Public Disclosure Authorized - World Bank · 2016. 7. 14. · Ash Handling System Comprehensive...

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FINAL REPORT

Prepared by

SGS India Private Limited Kolkata

March 2008

Comprehensive Environmental Audit and Due Diligence Assessment of the Bandel Thermal

Power Plant

CONTENTS

1 .O BACKGROUND

2.0 APPROACH & METHODOLOGY

3.0 COMPLIANCE STATUS AND MONITORING

4.0 POLLUTION PREVENTION & CONTROL ASSESSMENT

5.0 RESOURCE EFFICIENCY ASSESSMENT

6.0 OCCUPATIONAL HEALTH & SAFETY

7.0 POTENTIAL LIABILITIES

8.0 INSTITLTIONAL CAPACITY ASSESSMENT

9.0 IDENTIFICATION OF INTERVENTIONS

10.0 INVESTMENT PLAN

ANNEXURES

1 PREVIOUS MONITORING DATA

2 RESULT OF MONITORING / ANALYSIS DONE DURING THE STUDY

3 FIRE FIGHTING DETAILS

4 COMMUNITY REACTION

5 STANDARDS RELATED TO THERMAL POWER STATIONS

6 AUDIT ACTNITIES

7 REFERENCES FOR AMMONIA INJECTION

1.1 Introduction

1.2 Location

1.3 Environmental Settings

1.4 Major Plant Units for Units 1 -4

1.5 Description of Unit 5

Comprehensive Environmental Audit and Due Diligence Chapter 1 Assessment of the Bandel Thermal Power Plant -

1.1 Introduction

West Bengal State Electricity Board after its formation in 1955 embarked upon the first major thermal power plant project in West Bengal. The project was inaugurated in 1962 to install four (4) 82.5 MW units at Tribeni near Bandel and all the units were commissioned by 1966. A fifth unit of 210. MW was established in 1983. The power station named Bandel TPS is now under West Bengal Power Development Corporation Limited (WBPDCL).

The Government of India (GOI) has launched a new programme "Partnership for Excellence" targeting poorly performing coal fired state-owned power plants. The programme involves development of an effective operations and maintenance (O&M) approach followed by a plan for renovation and modernisation (R&M).

WBPDCL intends to carry out an Environmental Audit and Due Diligence study for the Bandel TPS to provide input to the proposed R&M scheme for the Bandel TPS. Though the study has focussed specifically target Unit 5 as this is being proposed for rehabilitation, the environmental aspects of other units have also been considered where necessary.

WBPDCL ------I West Bengal Power Development Corporation Ltd., fully state owned company was incorporated in July 1985. The main object of the company is to carry on business of Electric power generation and Supply. It has achieved from zero to best bloom by the advent of new millennium.

The authorized share capital of the company is Rs.2500 Crore divided in to 25000000 equity shares of Rs.1000 each and the Paid up Capital is Rs. 1663.76 Crore.

WBPDCL normally sells its generated power only to WBSEB for distribution. With installed capacity as on date is 2900 MW, it shares 62% of the state sector capacity. The power plants run by WBPDCL are

Kolaghat Thermal Power Station (KTPS) - 6 X 210 MW

Bakreswar Thermal Power Station (BKTPP) - 3 X 210 MW

Bandel Thermal Power Station (BTPS) - 4 X 80 MW + 1 X 120 MW I 1 Santaldih Thermal Power Station (STPSI - 4 X 120 MW 1

SC S SGS India Private Limited

Comprehensive Environmental Audit and Due Diligence Assessment of the Bandel Thermal Power Plant I Chapter l I

1.2 Location:

Bandel TPS is located near Tribeni town in the district of Hugli in West Bengal. and is about 50 km from Kolkata. Bandel, from which the power plant gets its name, is another nearby town which is the nearest major railway station on the main Howrah - Delhi railway line of Eastern Railway. Nearest railway station however is Kuntighat on Bandel - Katwa branch line of Eastern Railway. The area is included in the Triveni Chandrahati Gram panchayat. Its latitude and longitudinal extents are 22'54' N and 88'24' E, respectively. The neighborhood of the thermal power plant includes Triveni Tissue Township, Bansberia Municipality, Chandra Hati Gram Panchayet No. 1 and 2, Kuntighat, benipur, Raghunathpur. Triveni is well connected by metalled road. The Grand Trunk Road (National Highway No. 2) runs about 2.0 Km from the plant.

The plant is situated on the western bank of river Hugli (also called Ganga), about 1 km away from Assam road. It is connected to National Highway 2 by Assam Road and then Delhi Road.

Figure 1.1 shows the location in the country and state and 1.2 shows the places in vicinity of the site.

Table 1.1 Salient Features Of The Site

Location

Longitude P

Latidude

A1 titude

I Nearest Highway 1 Assam Road joining NH-2, about 500 m away

Near Tribeni, District Hugli, West Bengal

88'24' E

22'60' N

3 m above MSL

Topography

Seismic Zone

Nearest Railway Station

I Nearest City 1 Kolkata I

Gangetic plain

I11

Kuntighat on Bandel - Katwa Branch line of Eastern Railway.

I I ____( 1 Nearest Town [ Tribeni & Mogra

I

Nearest Airport 1 Netaji Subhas International Airport at Kolkata L

National Park 1 Sanctuary within 10 km None

Forest land within 10 km

Major Water body within 10 km

Historical Place I Monument

$G$ SGS India Private Limited

None

Hugli (Ganga) river by the side of the plant.

Hanseswari Temple at Bansberia, about 4 km towards south

2


1.3 Environmental Settings

The plant site is located in a flat alluvial plain, 3 m elevated above the mean sea level, within the lower orbit of the Gangetic delta. The present location is a mix of industrial, agricultural and semi-urban areas. The river Ganga is the major watercourse nearby. The region on the other side of the river is also a mix of industrial, agricultural and urban areas. Kalyani city and industrial area is about few kilometres away on the eastern side of the river.

Area being located less than a degree of the Tropic of Cancer is at the limit of the torrid zone. With some variations the temperature remains high throughout the year. Three seasons can be identified in which are:

Winter season from November to February

Summer Season from March to almost mid June

Monsoon Season from mid June to mid September extending sometimes to October.

A post-monsoon season is also sometimes considered between October to November. On the whole the climate bears the features of a tropical region.

The nearest meteorological station of Kolkata of India Meteorological Department (IMD) is at Alipore. Important meteorological conditions as found in IMD observations are presented below

Season Summer Monsoon Post Monsoon Winter

The region under study experiences a quite humid and hot summer but not so cold winter and quite good rainfall. Strong wind is experienced in summer and on the eve of monsoon and wind speed falls during post monsoon and winter. Calm condition is predominant during winter season. Wind blows predominantly from Southwest.

Wind Direction South, South west South, South west North, North West North, North West

Mean Temperature

Figure 1.3 presents the satellite overview of the plant and surroundings

Figure 1.4 shows the site map of the plant and surroundings

Maximum Minimum

36.3 O C 13. 7OC

Average Annual Rainfall 1581 mm

SGS SGS India Private Limited 3

i @ I Comprehensive Environmental Audit and Due Diligence Assessment of the Bandel Thermal Power Plant

1.4 Major Plant Units for Unit 1 to 4

The first unit of this power station of 82.5 MW capacity was commissioned in 1965. The other three of same sized were commissioned within 1966. All these four units were built under US assistance. At present the first four units has been derated to 60 MW each from 82.5 MW each.

Date Of Commissioning

Unit 1 : 4 February 1966

Unit 2: 23 December. 1965

Unit 3: 17 September, 1966

Unit 4: 1 October. 1966

Design Specijcations: Unit I to 4

Steam Generator

Make: The Babcock & Wilcox Co, USA Nominal rating: 625,000 Ibshr Superheater outlet temperature : 1010 OF Superheater outlet pressure : 1500 psi

Turbine

Make: Westinghouse Electric International Co, USA

Capacity: 82.5 MW

Speed: 3000 rpm

Maior Auxiliarv Units and Utilities

Coal Handling Plant

It comprises of Rotary Wagon Triplers. Conveyors system, Crusher Plant and Stackers

Demineraliser Plant

Groundwater is pumped by deep well pumps and is supplied to demineralisation plant. It consists of cation and anion exchange units with degasifier. DM water is mainly used for steam generation.

SGS India Private Limited

Cooling water intake and discharge

m

Cooling water for condenser is directly taken from river Hugli and used for once- through cooling system. Hot water is discharged to the river through underground discharge channel.

Ash Handling System

Comprehensive Environmental Audit and Due Diligence Assessment of the Bandel Thermal Power Plant

Fly ash from combustion is separated from the flue gases by mechanical dust collector and then through Electrostatic precipitator (ESP). Fly ash is at present collected and transported pneumatically to the ash silos for storage and further disposal. Bottom ash is disposed as slurry with high pressure water and then the sluny disposed to the ash pond. There are two (2) ash ponds which are alternatively used for deposition of fly ash and drying. Ash is finally excavated for further disposal.

Chapter 1

Stacks

There 4 stacks, one stack for each unit. 4 stacks for Unit 1 to 4 are 60 m high.

1.5 Description of Unit 5

The fifth unit of 2 10 MW was commissioned in 1983.

Design Specijcations: Unit 5

Steam Generator

Make: ACC-Vickers-Babcock Superheater outlet temperature : 540°C Superheater outlet pressure : 136 kg/cm2

Turbine

Make: Bharat Heavy Electricals Ltd Capacity: 2 10 MW Speed: 3000 rpm

Stack

Single stack of 120 m high


General Description Of The Plant

llOCL

The 210 MW extension stage of B.T.P.S. has been designed on the concept of unit system where a single steam generator supplies steam to a single turbine coupled to an A.C. generator connected to the 132 KV station bus.

Steam Generator Plant


The A.V.B. make steam generator is of single drum, water tube, natural circulation type with super heaters and R.H. The max continuous evaporation of the steam generator is 700 tonshr. at 136 K ~ / c ~ ~ ~ and 5 4 0 ' ~ super heater out let pressure and temperature with the final feed water temp of 247'~. The Max. reheater flow being 605 tonhr. The water cooled furnace walls, super heaters, Reheaters and the Economisers being self contained construction and are suspended from a supporting structure.

Chapter 1

Turbine Generator

The B.H.E.L. Make C-210-130 model 210 MW turbine is Condensing, tandem, Compound 3 cylinder impulse type machine with nozzle-governing and regenerative feed heating. The double flow L.P. turbine incorporates a multi-exhaust baumann stage in each flow. The steam after expanding through the twelve stages of the H.P. turbine is reheated in the re-heater and return to the I.P. turbine through interceptor and I.P. Control valves. After expanding through the eleven stages of the I.P. turbine and four double flow stages of the L.P. turbine, it is exhausted to the twin surface condensers welded directly to the exhaust part of the L.P. turbine. The rated output of the turbine generator set is 210 M.W. with main steam-parameters before the E.S.V. being 130 ata and 53.5'~ steam flow at valve wide open condition is 670 tonshr. The Reheated steam temp. is 53.5'~ at inlet to the interce tor valves. Quantity of i: Circulating water required through the condenser is 27000m h r .

The H.P. and I.P. rotors are connected by a rigid coupling and have a common bearing. The I.P. and L.P. rotors are connected by a semiflexible coupling.

The cooling water supplied to the condensers is provided by 3 nos. 33.113% capacity circulating water pumps taking suction from the River Hooghly and located in the Intake Pump house of the River bank. The cooling water at the rate of 28500m3/hr. after picking up the heat from the turbine exhaust steam, is discharged back into the river's through tunnels.

The D.M. Plant consisting of two trains of Pressure filter, Primary and Secondary cation units, anion units and mixed bed polishers supply high quality water to the steam cycle make up and the make-upto the closer cycle, D.M. Cooling System.

The high pressure ash water pumps and fire fighting water pumps are situated in the Ash water pump house and take suction from the ash water sump, which in turns is located on the circulating water return channel. The requirement of compressed air for

SGS India Private Limited 6

Comprehensive Environmental Audit and Due Diligence Chapter 1 Assessment of the Bandel Thermal Power Plant

WDmOL

various instrument, drives and for misc. services are met by 2 nos. instrument air compressors and two nos. plant air compressors. Both the systems are provided with an air drying equipment each.

The fly ash in the boiler is collected in Electrostatic Precipitator located in the flue gas path between air heater and I.D. fans. The bottom ash is collected in a water impounded hopper located at the bottom of the furnace.

The fly ash removal is by a hydropneumatic system consisting of an air seperator, hydroexhauster and dry ash-transport lines, Dust extraction valve etc and is automatic sequentially operated. The bottom ash is removed by hydroejecting system, which, utilizes the high velocity water to remove the ash after being crushed by clinker grinders located below the ash hopper.

The fuel requirement of the unit about 3000 ton per day, is met by the extension C.H.P. The coal which arrives at the plant is wagons is unloaded by the wagon tipplers and transfer to the boiler bunkers is achieved by a duplicate chain of coal conveyors along with crushers, transfer point etc. The extension unit C.H.P. is linked with existing system in such a way that the extension system of conveyors can be utilized to feed the existing boiler bunkers also. There is a provision of adding one more wagon tippler in the future.

Cooling Water System

Condenser cooling water system

At full load operation of the unit, about 480Thr. of steam is exhausted in to the twin surface condenser. About 27000M3hr. of Cooling water is required for condensing this exhausted steam. The cooling water is supplied by 3 nos. 33.113% capacity, vertical mixed flow pumps of 9500M3hr. capacity each at 16.6 MWC head. These pumps are located in the intake pump house situated on the River bank by the side of the existing intake pump house. Water from the river flows into the individual pumps suction basin through trashrack, inlet gates and travelling water screen. The travelling screens arrest the floating and suspended debris from the water and bring them up where they are washed with high pressure water jets, the wash water being supplied by the screen wash pumps provided for that purpose. There are five nos. of Traveling Screens one each in the suction of the 3 C.W. pumps and two common for the four Raw Cooling water pumps and four screen wash pumps.

All the pumps discharge into the common 2.2 M dia C.W. header supplying water to the twin Condensers. The normal inlet and outlet of the Condensers are from the bottom and top respectively. The inlet and outlet are provided with motor operated butterfly valves. Even with provisions of water screens, the chances of blocking of the condenser tubes by debries cannot be completely ruled out. Hence an arrangement for back-washing by reversing the flow through the tubes has been incorporated with two more butter-fly vlvs in each condenser. All the four valves of each condenser can be



operated in group by the selector switches or individually by push buttons. The controls are provided at the local pannel.

The outlet from the condenser is returned to the down stream side of river through concrete tunnel and discharge weir.

Auxiliary Cooling water system

4 Nos. Raw Cooling water pumps are provided for meeting the cooling water requirement of 5 nos. turbine Oil Coolers and 8 nos. D.M. C.W. heat exchangers. The pumps are vertical mixed flow type and have a capacity of 2400 ~ ~ / h r . e a c h , at 33.53 MWC head. Two pumps are sufficient to meet the full load requirements ant two remain stand by.

Coal Handling System

The daily requirement of coal for the extension stage is estimated to be between 2500 to 3000 tons depending on the calorific value of coal at full load. For unloading and feeding this coal to the power house bunker, one duplicate chain of coal conveyors has been arranged along with crushers, transfer point, each with a capacity of 500 tonhr. Separate arrangement has been provided for ventilation and dust collection for improving operation conditions. Adequate interlocks and protections have been arranged for safety of men and equipment.

The system has been inter with the existing system to improve flexibility and keep investment to a minimum with the interlinking and modification provided in the system, it will be possible to use existing wagon tipplers for extension unit. Also belt conveyor system for the extension unit can be made use of for supplying coal to the bunkers of the existing units of the power station. However, provision has been kept for addition of one more wagon tippler in the future.

Service Water System

1. Station service water system

The Service water system is designed to meet the requirements of the following:

i 1 ii) iii) iv) v) vi) vii) viii)

Drinking water in various locations Miscellaneous services in coal handling plant. Diesel engine flushing tank of the fire water system Make up supply to air conditioning plant. Ash handling plant - Misc. services. Sealing and lab water supply to circulating water pumps. Supply to the air ejector in the Stator water expansion tank. Toilets at various locations.

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Comprehensive Environmental Audit and Due Diligence Assessment of the Bandel Thermal Power Plant I Chapter l I

The system consists of headers and risers with isolating vlvs in each branch, around the unit. The system is also interconnected with the existing stations service water header.

Two (2) nos. pumps of 100 ~ ~ / h r . capacity each, at 72 M.W.C. pressure are provided which take suction from the well water tanks. The pumps are started manually from their M.C.C.S.

2. D.M Service water svstem

Two (2) nos. D.M. water service pumps of 60 ~ ~ / h r . capacity at 36 M.W.C. pressure have been provided for supplying make up to D.M. cooling water system and for supplying make up to D.M. cooling water tanks (2 nos.).

The pumps take suction from the condensate storage tank.

Normally one of the pump is running and the other remains as standby. They are started from the U.C.D. and have provision of Automanual selection. On 'Auto' the pump starts automatically whenever the pressure in the common discharge header falls or the running pump trips.

Water Treatment Plant

Because of blowdown, system losses etc., the heat cycle requires a make up. High quality treated water must be fed to the heat cycle a make up.

All natural waters leave a residue of mineral matters when evaporated. Scale forms on heat transfer surfaces because of prolonged deposition of these mineral residues. Scale has a very much low thermal conductivity (average about 5% of the conductivity of steel and for some porous scalesit goes down possibly below 1 percent) and forms fastest at points of greatest heat input. Scales therefore impede heat transfer which may results in over heated boiler tubes and consequent outages due to tube failures. Modem-high pressure boilers with very high rates of heat input cannot stand any amount of scaling in its heat transfer parts.

For 5'h Unit extension at B.T.P.S. deminaralised water is necessary not only for power cycle make up but it is also required for closed cycle auxiliary cooling circuit make UP-

For 5' Unit, the water treatment plant has two chains each, of 35 ~ ~ / h r . capacity. There will be provision in the lay-out for installation a third chain of same capacity.


Ash Handling System

- In large steam generators using low grade coal with 33-35% ash as fuel, collection and disposal of ash poses a serious problem. The daily ash production of 210 MW boiler may be about 1000 tonnes. Normally the coarser (bottom) ash about 20% is collected in the water impounded hopper at the bottom of the boiler furnace. The finer (fly) ash flowing out with the flue gas is separated in dust collectors placed in the gas path and collected in hoppers placed below the dust collectors. The ash handling system carries out the function of removing the ash thus collected in the bottom ash hopper and the fly ash hoppers and disposing the same conveniently to the allocated disposal area away from the main power house.

In the 210 MW extension boiler, a hydro pneumatic system of ash removal is provided for fly ash hoppers placed below the stack, Electro-static precipitators and the air heaters. For removing the ash from the bottom ash hopper hydro-ejectors are provided. The coarser fly ash, which, collects at the bottom of forced flow section, is collected in a water-impounded hopper from where it is camed to the bottom ash hopper by ejectors to remove along with the bottom ash.


The system consists of: -

Chapter 1

i) Ash water system

ii) Bottom ash system

iii) Fly ash system

Ash water system

Three nos. ash water pumps are provided, which, take suction from the ash water sump and supply water to the 4 nos. hydro-vactors of the fly ash collecting system, to flushing water lines to bottom ash hopper and coarse ash hoppers and to the hydroejectors of the bottom ash removal system.

Bottom Ash Removal System

The Coarser bottom ash, about 20% of the total ash, is collected at the water impounded hopper at the bottom of the furnace. The hopper is provided with a continuous make up water supply and overflow to keep the temperature of the water low. The 2 nos. hydraulically operated gates provided at the front and rear of the hopper opening discharges the clinkers and water in to the double row grinders placed below Hydro ejector, where the energy of high pressure water supplied by the ash water pumps is converted into velocity energy, are provided below each grinder chamber. The high velocity water carries the ash slurry discharging from the grinder, to the disposal site through 2 nos. slurry transport lines. 8 hours cycle of cleaning bottom ash and coarse ash is considered sufficient when the boiler is on full load.

, SGS India Private Limited

Comprehensive Environmental Audit and Due Diligence Chapter I 1 Assessment of the Bandel Thermal Power Plant

Fly ash removal system

Fly ash collected in 12 nos. air pre-heater hoppers, 24 nos. E.S.P. hoppers and one no. stack hopper is removed by a hydro-pneumatic system. It consists of two nos. air separators with two nos. hydro-vectors each. The high pressure water for the hydro- vectors is supplied by ash water pumps. The two air separators through their hydro- vectors are connected to two chains of dry ash transport lines. Six no. A.P.H. hoppers and 12 nos. E.S.P. hoppers are connected to each chain of the transport lines through Material handling vlvs (MHV) and a system of segregating vlvs (Sv). The stack hopper is connected to chain 'B'. Two nos. Cross over valves (C.V.) are also provided to interconnect both the chains, so as to facilitate cleaning of hopper of one chain through the air separators and hydro-vactors of the other chain. An air intake is provided at the end of the each branch of transport lines to admit air for conveying the ash discharging from the hoppers. The E.S.P. hoppers are provided with Ash fluidizing air supply pads on the sides to dislodge the sticking and stagnant ash inside the hopper. Air to the pads is supplied by 2 nos. air blowers through solenoid vlvs (F.A.S.V). The fly ash removal is canied out either by automatic sequential system or remote manual.

H.P. water supply for the hydro-vactor is from the ash water pumps. The automatic operation of the system is controlled by a series of pressure switches and timers. The cleaning of the hopper is taken up in sequence, one chain after another and again in the chain selected, one hopper after another, starting from the boiler side. Selector switches are provided to select the exhauster and the chain. With the starting of the hydrovactor the ash transport line goes under vacuum and the air from atmosphere flows into the system. At a preset value of vacuum, one M.H.V. opens and cleaning of the hopper is started when the hopper is practically cleaned, the vacuum with system drops and at a preset value the solenoid (F.A.S.V.) for the hopper opens and fluidizing air is admitted to the hopper to dislodge the ash on the sides of the hopper. Thus when the system vacuum maintains at a preset low value for a preset time interval the hopper is fully cleaned and change over to the next hopper in sequence.

The air ash mixture thus drawn in get mixed with water down stream of the hydro- vactor and the slurry discharge into the air separator, where the entrained air is vented to atmosphere and the slurry is discharged to the disposal site via the same set of disposal lines as for the bottom as removal system. The two ash disposal lines are provided with cross over v/vs (ASLCV) to facilitate using either of them in any combination.

S S SGS India Private Limited 11

Location in India and the State

WEST BENGAL. INDIA

GAY ESH PUR

Figure 1.3 : Plant and its surroundings satellite map

CAHAPTER 2.0

2.1 Environmental Audit and Due diligence

2.2 Stages of EA

2.3 Work Plan for EA and Due Diligence Study

2.4 Monitoring Plan

2.5 Monitoring Protocols

Comprehensive Environmental Audit and Due Diligence Assessment of the Bandel Thermal Power Plant 1 Chapter2 I

2.1 Environmental Audit and Due diligence

Environmental audit (EA) is intended to quantify environmental performance and environmental position. In this way they perform an analogous function to financial audits. EA is the final phase of environmental management. Conducting an environmental audit is no longer an option but a sound precaution and a proactive measure in today's heavily regulated environment. Indeed, evidence suggests that EA has a valuable role to play, encouraging systematic incorporation of environmental perspectives into many aspects of an organisation's overall operation, helping to trigger new awareness and new priorities in policies and practices.

IS0 14001 defines an environmental eudh as: A systematic, documented verlflcatlon process for objectively

obtalnlng and evaluating evWence to determine whether

specified envimmenM activtties, events, condltlons,

management systems or hvfonnation about these matters

MHIforms with audit crrtwEa, and connnunlcatky( the results of

this process to the cliswrt.

Environmental auditing focuses on: Assessing compliance with relevant statutory and internal requirements Facilitating management control of environmental practices Promoting good environmental management Maintaining credibility with the public Raising staff awareness and enforcing commitment to departmental environmental policy Exploring improvement opportunities Establishing the performance baseline for developing an Environmental Management System (EMS)



2.2 Stages of EA

Environmental Audit follows basically three sages - Pre-Audit, Site Activities and Post-Audit

Pre-audit activity is the planning of the auditing programme which takes into account of the following:

Finalising the scope of work Familiarisation with plant process Development of the audit team Establishing a work schedule Prioritising the audit topics Pre-audit site visit Review Background Information

Site Activities include Detailed Site Inspection Collection of required data related to environmental compliance, monitoring, plant performance, safety, public complaint etc. Interview related plant personnel Review audit evidence Select monitoring locations, parameters, frequencies, methods etc. Carrying out on-site monitoring

Post Audit activities include

Collate all information Prepare Draft Audit Report Circulate Draft Report and arrange meeting Finalise Audit Report Develop action Plan

2.3 Work Plan for EA and Due Diligence Study

Based on the proposed scope of work and the steps for environmental audit and due diligence, following work plan has been made as given in Table 2.1.

SGS SGS India Private Limited

Table 2.1 Work Plan


Chapter 2

Preliminary Site Visit and Assessment of Data

Gaps

1 1 analysing the data monitored during study, the compliance status 1

A kick-off meeting to decide on the mode of interactions between the plant officials and the consultant. The plant units and the surroundings will be visited and all relevant documents relevant to environmental issues will be preliminary noted to find out the

Monitoring & Analysis Compliance Assessment

data gaps Will be canied out in accordance with standard methods

, After reviewing the existing environmental documents and

I assistance and emergency will be studied. Potential Liabilities 1 A survey of local resources liable to be affected due to operation

( of the plant will be assessed. Pollution Prevention &

Control Assessment

Resource Efficiency Assessment

Occupational Heath &

2.4 Monitoring Plan Monitoring of environmental parameters is the best option to ensure better environmental management. Monitoring helps to find out

Compliance with standards for disposal for different effluents Performance of pollution control measures Effluent sources need to be monitored Need for further improvement in pollution control

During compliance assessment study and initial study of the plant environment, further requirement for pollution prevention and control will be assessed to meet the statutory requirement and also Corporate Social Responsibility This will be canied out simultaneously with the above study for optimum use of resources and minimizing energy uses. Plants health and safety records will be reviewed, On-site

1 Institutional Capacity Assessment

Identification of Interventions Preparation of

Investment Plan

Thus monitoring serves as the major tool for environmental audit

Safety Assessment I emergency plan will be reviewed. Infrastructure for medical

of the plant will be carried out. Community interaction meting will be arranged to obtain all stakeholders view on the risks. Existing infrastructure for environmental management will be reviewed and requirement for improved institutional capacity for this purpose will be assessed. All these studies will lead to some specific suggestions and those will be compiled and its economic aspects will be considered. A cost break up of the suggested interventions will be made.

Initial Monitoring Plan as per scope of work was revised after plant visit. This was further fine tuned during actual implementation. All locations for monitoring were visited before sampling.

As the plant carries out a number of monitoring as suggested by West Bengal Pollution Control Board (WBPCB), for comparative study those locations have been considered for this study. Besides those locations a number of new locations for

. SGS India Private Limited

Comprehensive Environmental Audit and Due Diligence 1 Chapter 2 Assessment of the Bandel Thermal Power Plant

.IyDcL

various monitoring have been chosen depending on meteorological condition, sensitivity and other criteria. The monitoring plan is given in Table 2.2.

Table 2.2 Environmental Monitoring Plan

Environmental Aspects as mentioned in

Stack Emissions

Quality

Process Effluent I- Effluent

Sewage Effluent from k I E;o;ynd

1 Treated Sewage

Surface Water Quality

S02, NOx, PM, PM-10, Hg

S02, NOx, SPM, PM- 10, Hg

pH? Temperature, Chlorine, Suspended solids, Oil & grease, Chromium, Copper Total), Iron (Total), Zinc, Phosphate, Hg pH, Temperature, Chlorine, Suspended solids, Oil & grease, Chromium, Copper (Total), Iron (Total), Zinc, Phosphate, Hg

SS, BOD, and relevant other parameters

SS, BOD, and relevant other parameters Standard Water quality parameters

Parameters

All stacks

5 (2 inside the plant and 3 outside the plant)

(Condensor Cooling, Boiler blow down, cooling Tower blow down, ash slurry, coal yard effluent)

No of Locations

5 (All outfalls in the river)

No of days

Samples per day

STP Outlet

3 (Water body receiving plant discharges and the pond close to the

Remarks

4 Stacks of Unit 1 to 4; If Unit -5 is operational then its stack will also be monitored 1. Admin Bldg Locations have 2. CHP been selected 3. BTPS township based on Air 4. Mogra College shed region and 5. Nearby Club sensitivity

Justification

Area Drain sources of

thermal power

1 .Cooling Water Outfall, 2. Ash pond water & Township sewage combined outlet 3. Neutralising Pit outfall 4. Pump cooling, laboratory drain etc outfall 5. Plant surface

plant

These are the 5 outfalls in the river Hooghly. Sample may not be always available in point 5.

1 drain outfall. I I Given in TOR

but Not required as there is no 1 3 1 At the Plant pump 1 1 house for seiage- 1

water 1. River water 50 m The river is a down stream of the tidal one. final outlet at the Monitoring to


Comprehensive Environmental Audit and Due Diligence Assessment of the Bandel Thermal Power Plant I Chapter I

t -GaxiF 1 Quality

Source Noise r-- Ambient Noise I-- Coal Quality r Local Soil I- (River, Hooghly)

Standard Water quality parameters including Hg

Standard Parameters including Heat Value, Ash

Parameter including Trace elements e.g Hg, Texture, Cation Exchange Standard parameter including Turbidity Hg

ash pond)

1 (Near the ash pond)

All Generators

4 (2 inside plant and 2 outside plant)

2 (during day and during night)

2. River water 100 m upstream of the first outlet at the time of monitoring 3. Pond water by the side of ash pond towards river

tide and low tide

Tubewell water rn I operators cabin

3 1 1. Administrative

3

building 2. Where many workers work 3. One at nearby residential area 4. One at nearby

1. 3 m away from the generators and also inside the

I commercial area

2. Field away from the plant

3

surface water quality

1. Agricultural field near Ash pond

2.5 Monitoring Protocols

All standard procedures for monitoring of different parameters for different environmental aspects are given in Table 2.3.


Monitoring Mercury:

- Monitoring approach for mercury is given below, as this is not generally measured in India

Mercury (Hg) is not included in the list of pollutants to be monitored for Thermal Power Plants generally. There is no Indian regulation on that and World Bank also has no regulation on mercury (ref: Pollution Prevention and Abatement Handbook 1998). However there has been recent concern on mercury emission to atmosphere in general and particularly from coal-fired power plants. The main human health hazard of mercury has been associated with exposure to highly toxic organic methylmercury through food, primarily through the ingestion of aquatic organisms, mainly fish. Atmospheric mercury, mostly in vapour form has less significant impact on human health.


To assess the mercury emission and its dispersion into environment, it has been planned to monitor mercury from the starting point to the final destinations. This can be shown as

Chapter 2

Stack emission + Atmosphere + Deposition on surface water

Hg in Coal -+ / 1 Ash pond + leaching to ground water


Comprehensive Environmental Audit and Due Diligence Assessment of the Bandel Thermal Power Plant I I

Mercury Monitoring Methods


Table 2.3 Monitoring Protocols


Accuracy -iKz-

Chapter 2

1 1 1 2.6mgNrn3-5000 obtained 1

I I i I 1 obtained i

SO2 (IS: 1 1255 (Part 2) 1 10%of

mglNm3

NOx 11s: 11255 (part 7)

I (1999) and 9276 - 1 (1998) : I Instrumental Method by

value

2 ppm-5000 ppm 1 value

Stack Emissions

l~article Size Analyser I I 1 10%of

1 10%of

i 1 i I I obtained i

PM PM-10

1 1 1 hrs. sampling@ 0.5 Iprn obtained 1

IS:11255 (Part 1 and 3) IS0 standard : 13320-1

Hg

4 mg/Nm3- 100 gmINm3

US EPAlOlA

AAQM

Coal Ash 1 USEPA 3050 B (GEN. 0.5-2.0 mg/kg + 10% SOPlCALLABl69) Below 2.0 mg/kg + 5 %

obtained value

APHA 21 st EDN. 2005

APHA 21st EDN. 2005

0.10- 1000mg/m3 03-1050mg/m3for8

SO2

NOx

~SPM '1~:5182 (Part - N)

value 10%of

PM-10

Hg

IS:5182 (Part - 11)

IS:5 182 (Part - VI)

' 4 - 5000 mg/ m3

4 - 500 mgl m3

0.02 to 500 mg/ m3

NAAQMSl2512003-2004 (CPCB)

APHA 3rd Edn. Method No. 317

APHA 2 1 st EDN. 2005 0.1 -5940 Chlorine (3500-Ca-B) 2.1 - 10 mg/l P


value 10%of

obtained value 5% of

obtained value

Suspended solids Oil & Grease

through 25 ml TCM 05 - 750 mgl m3 for 8 hrs.

sampling @ 0.5 lpm through 25 ml NaOH & Na2 & As02 solution

value

10% of obtained

value 10% of

obtained

APHA 21st EDN. 2005 (2540 D) APHA 21 st EDN. 2005

2 - 1000 mgA

Above1 O00mgA 2.0- 10mgA

* 10% 5%-

? 10%


Chromium

Copper (Total)

APHA 21 st EDN. 2005 0.1 - 10 mg~l + 5 % 1

APHA 21 st EDN. 2005 0.05 - 20 mg/l + 10% Phosphate (4500-P-D) Above 20 mgA 5%

APHA 21 st EDN. 2005

(5520B)

APHA 21 st EDN. 2005 (3 1 1 ID)

APHA 2 1 st EDN. 2005

~ llron (Total) (3 1 1 18) Above 50 mgA 5%

0.1 - 50 mg/l

Hg

pH

Temparature

Chlorine

Suspended Solids

Oil & Grease

Above 10 mgA 0.05- lOmg/l Above 10 mgjl 0.02-50 mg/l

+ 5 %

SGS India Private Limited la

Treated Process

APHA 21 st EDN. 2005 (31 12B) APHA 2 1 st EDN. 2005 (4500-H-B) APHA 21 st EDN. 2005 (2550 B)

APHA 2 1 st EDN. 2005 (3500-Ca-B)

APHA 21 st EDN. 2005 (2540 D)

APHA 21st EDN. 2005 (5520B)

20

5%

+ 5 % 5 % I + 5 %

5 %

,

'0

0.01 - 5 mg/I Above 5 mgA

1-14.

0.1 - 2.0 mgA I

2.1 - 10 mg/l 2 - 1000 mgA

Above1 000mgA I

2.0- 10mgA 1 Above 10 mgA

+ 20% 20%

+ 0.10

+ 5 % 5%

+ 10% 5%

+ l o % 5%


I Chapter I

B.0.D @ 1 1.0-1000mgA f 15%

27°C for 3 IS 3025: PART 44,1993 Above 1000 mgll 15% (Reaff. 1999)

f 0.10 * 10%

5%

Surface Water Quality

I I

Alkalinity APHA 21 st EDN. 2005

1-14. I 10 - 100 mgA

101 - 500 mg/l

pH

5% 1 5%

~ m m o n i a (as APHA 2lst EDN. 2005 1 5.1 - 100.0 mf l

l(3500-~a-B) Above 1000 mgA 10%

APHA 21st EDN. 2005 (4500-H-B)

NH3 - Free)


(4500-NH3-B&C)

I ' * 5 % 1 Chlorides (as APHA 21st EDN. 2005 100.1 - 500 mg/l 2%

(3500-Ca-B) Above 500 mgA 2%

Above 100.0 mgll

Surface Water

Chromium (as Cr)

Colour

Quality

APHA 21st EDN. 2005 (31 11D)

Conductivity APHA 21st EDN. 2005 1@25OC 1 (2510 B)

101 - 500 pslcm 5%

0.05 - 10 mg/l 1 Above 10 mg11

f 5 % 5%

* l o % 10%

+ 10%

APHA 21st EDN. 2005 (2 120 B)

1-50 HU Above 50 HU 5 - 100 y slcm

Above 10 m d

Comprehensive Environmental Audit and Due Diligence Assessment of the Bandel Thermal Power Plant - I

Chapter 2

PHA 21st EDN. 2005

Nitrate (as LO.)

Odour

0.5 - 10.0 mgA

~ u l ~ h a t e (as sod) T.S.S

+ 10%

- - r Sfis SGS India Private Limited

APHA 21 st EDN. 2005 (4500-S04-E) APHA 21st EDN. 2005

22

APHA 21st EDN. 2005 (4500-N03-E)

APHA 21st EDN. 2005 (21 SOB)

APHA 21st EDN. 2005

2 - 100.0 mg/l Above 100 mg/l 2.0 - 1000 mgA

+ 5 % 2%

5 10%

Above 40 mg/l

Objectionable1

Unobjectionable

2.0 - 10 mgA

I - 5 %

--

5 10%


10%

* 5 %

CaC03) Total

Above 1000 mgA I

10 - 250 mg/l

Temperature

Total

Ground Water Ouality (As per IS

105*)

IMBAS) I&c) Above 0.5 mg/l 10%

(2540 D)

APHA 2 1 st EDN. 2005 (2550 B)

(234OC) APHA 2 1 st EDN. 2005

(as Al) Anionic Detergents (as

118:3025 P37 1988 (AAS 0.005 - 5.0 mg/l I & l o % (Arsenic (as Cold vapour)/ APHA 21 st 1

Dissolved Solids Total Hardness (as

Above 1000 mgll 1 10%

1 - 100 mz/l 1 * 2 0 %

APHA 21 st EDN. 2005 (2540C) --- APHA 21st EDN. 2005

-

Nitrogen (as (4500N ORG B, 4500 NO3 N) E )

21st EDN (31 1 ID)

IS: 13428 -1998 Annex K 1 APHA 21 st EDN (5540- B

Above 250 mg/l

1 .O - 1000 mgA

- Above 100 mgA

0.5 - 10 NTU

11 -4ONTU

41 - 100 NTU

0.02 - 10.0 mgll

Above 10 mg/l

10 - 100 rngn

101 - 500 mg/l

Above 500 mg/l

Turbidity -

Zinc (as Zn)

Alkalinity (as C~CO?)

Aluminium

AS )

Boron

10%

- + 10%

* 0.2 NTU

- + 0.5 NTU

- + 1.0 NTU

+ 5 %

k 5%

k 10%

* 5%

k 5%

APHA 21 st EDN. 2005 (2130B)

APHA 21st EDN. 2005 (3 1 1 1B)

IS 3025 F23-19861 APHA 21st EDN (2320 B)

IS 3025 P55-20031 APHA Above 10 mgA

0.05 - 0.5 mg/l

Cadmium (as Cd )

0.1 - 10.0 mg/l

10%

* 20%

EDN (3 1 114B)

IS 13428-1998 Annex H

Calcium (as

c a >

18:3025 P41 19921 APHA 21st EDN (3111B)

APHA 21st EDN (3500-Ca B Above 200 mgll

5 - 100.0 mgA

(Reaft2005)

Above 5.0 mgA

0.05 - 5.0 mgll Above 5.0 mg/l

pp

Chromium

SG $ SGS India Private Limited

10% * 5 %

5%

0.05 - 5 mg/l

Above 5 mg/l

100.1 - 500 mg/l 1 2%

Colour

Copper Colifoxm

* 5 %

5%

Above 500 mgll

APHA 21st EDN (31 1 ID)/ IS 13428- 1998 Annex J

2%

IS:3025 P-4 :I983 1-50 HU (Reaff:2005) Above 50 HU IS:3025 P42-1992(AAS 0.02 - 50 mgA

0.05 - 10 mgll

Above 10 mg/l

Direct)/ APHA 2 1 st EDN (3500-Cu) IS 540111s 151 85:2002

+ 5 % 1 5%

Above 50 mg/l

4 . 8 to > 1600 5% NA


WmmCL

I

AbsentIPresent

AASIAPHA 2 1 st EDN

Cyanide (as CN)

per 100 rnl.

0.02 - 0.20 mg/l

i SGS SGS India Private Limited

+ 5 %

IS:3025 P27 1986 I APHA 2 1 st EDN(4500-CNC&E) IS 5887(PART-1 )/IS

Manganese 35 of IS:3025: 1964 IAPHA (as Mn) 21st EDN 311 1B

0.2 - 5.0 mgA

Above 5.0 mgA

0.02 - 10 mgA 1 + 5 %

2%

2%

Above 10 mgA - 5 %


solids I(~eaffi2005) Above 250 mg/l 10%

Chapter 2

1 1.O-lOOOmA + 10% kzness (as IIS:3025 P 21 : 19831 APHA

10 - 250 mgA 1 + 5 % 1 I

Total Dissolved IS:3025 P-16: 1984

CaC03)

Turbidity

21st EDN-2340 C Above 1000 mgll 1 0 %

IS:3025 P-10 : 1984 11 -40NTU (Reaff:2005) 41-100NTU

Source Noise

Coal Quality Matter IS-1350 1.00 - 50.00 % ,+LO. 1 %

Zinc (as Zn) leq in dB(A) Day Time leq in dB(A)

Inherent Moisture

Ash content

~ i x e d Carbon 11s-1350 I bv difference I I

Moisture (As Received

By noise level meter

By noise level meter

ASTM-D5865 ASTM D 3684-Standard Method for Total Mercury in Coal by the Oxygen Bomb

Combustion1 Atomic Absorption Method.

Ambient Noise

IS:3025 P49-19941 APHA 2 1st EDN (3 1 1 1B) By noise level meter

Night Time leq in dB(A)

Heat Value

Hg Proximate Analysis: Total

IS-1 350 IS-1 350

1000-10000 Kcal

0.05 - 0.2 ppm

Ultimate Analysis:

Carbon

Hydrogen Nitrogen

0.02 - 10.0 mg/l

Above 10 mg/l

+ 40 Kcal

0.10+/-0.01 ppm

0.5 -20 .OO % 1 0.5 - 100 %

Oxygen Sulphur Mineral matter Total Moisture

+ 5 % I - + 5%

,+I-0.1% ,+I-0.1 %

pp

ASTM-D5373

ASTM-D5373 ASTM-D5373

c'% qc *3 %.- SGS India Private Limited

By difference ASTM-D5373

IS- 1350(1.1 X Ash)

IS- 1350

25

2.00 - 90.00

0.5 - 50.00 %

,+I- 1 %of the absolute value ,+I- 1 %of the

absolute value

0.1 - 10.00 %

0.1 - 10.00 %

calculation 1

1 .OO - 40.00%

0.1 - 10.00 %

,+I-0.03% ,+I-0.03%

,+I-0.5%


Alkalinity (as CaC03) Available Nitrogen (as N) Available Phosphorus

Potassium (as R.Hesse (GEN. K) SOP/CAL.LAB-38) 1-500 mgkg

(as P) Available

Cadmium (as USEPA 3050 B (GEN. Cd) SOPlCALLABl69)

APHA 21st EDN.:2005 Analysis of soil by P. R.Hesse (GEN. SOP/CAL.LAB-38) Analysis of soil by P. R.Hesse (GEN. SOP/C~.LAB-38) Analysis of soil by P.

25-500 mgtkg Above 500 mgKg

10 mgkg (Min)

10 mglkg (Min) 1 f 1 0 %

Chlorides (as APHA 21st 1-5 mgkg

Electrical Conductivity

+ 1 0 % + 5 %

f 1 0 %

c1)

Chromium (as c r ) Copper (as c u )

USEPA 3050 B (GEN. Lead (as Pb) SOPlCALLABl69)

0.5 - 106 10% -

EDN.:2005(4500-CI-B)

USEPA 3050 B (GEN. SOPlCALLABl69) USEPA 3050 B (GEN. SOPlCALLABl69)

( 1 5 w/v aq: ISODIS 11265 (GEN.

Above 5 mg/Kg

soln.)

Iron (as Fe)

(Min)

Texture:

Clay

f 5 %

1 0.1-10m g g k ' 5 1 0 %

SOP/CAL.LAB-38)

USEPA 3050 B (BY AAS) 1-100 mgkg

Above 100 mgKg

' SGS India Private Limited ~e, . .

Above 10 mg/Kg

0.1-5 mgkg

f 1 0 % f 1 0 %

C.A.Black - Soil chemical (GEN. SOP/CAL.LAB-38)

26

5 5 %

5 5 %

NA NA

lYDCL

CaC03)


chlorides (as APHA 21st EDN. 2005


Chapter 2

(3500-Ca-B)

Chromium (as c r )

Colour Conductivity @ 25°C

~ 1 ) 1 - 2%

100.1 - 500 mgA

Above 1000 mgll

5 - 100.0 m d

- 2%

APHA 21st EDN. 2005 (31 11D)

APHA 2 1 st EDN. 2005 (2 1 20 B) APHA 2 1 st EDN. 2005 (2510 B)

10% * 5 %

0.02 - 10.0 mgll Above 10.0 mgll

1-50 HU Above 50 HU 5 - 100 pslcm

101 - 500 pslcm 501 - 1000 p slcm

k 5 %

5% + l o % , 10%

+_ 10%

5% - 2%

'1100L

Copper


Dissolved

1 st EDN. 2005

Chapter 2

APHA 21st EDN. 2005 (3111B)

APHA 21st EDN. 2005

APHA 21st EDN. 2005 (4500-0-C)

Above 1000 pslcm

0.02 - 50 mgA Above 50 mgA

lHuoride (4500-F-D) Above 10 mgfl - 2% 0.1 - 10 mgll

Nitrate (as N03)

f 5 % 5% 1

1.0 - 30 mgll

Above 30 mg/l

& 5 % 1

Odour

Oil & Grease

VH

f 5 %

2% - 1

APHA 2 I st EDN. 2005 (4500-N03-E)

Selenium (as Se) Silica (as SiOz - Reactive)

Silver Sodium (as

APHA 21st EDN. 2005 (2 1 50B)

APHA 21st EDN. 2005 (5520B)

APHA 21 st EDN. 2005 (4500-H-B)


0.02 - 10 mg/l

Above 10 mgA

APHA 21st EDN. 2005

APHA 2 1 st EDN. 2005

APHA 21st EDN. 2005 (3111B) APHA 21st EDN. 2005

I 28

f 10%

- 5% Objectionable1 '

Unobjectionable 2.0 - 10 mgll

Above 10 mgfl

1-14

0.01 - 5.0 mgA

Above 5.0 mgfl 1.0 - 50 mgA

Above 50 mgA

0.1 - 1.0 mgA

Above 1.0 mg/l

1.0 - 500 mgA

--

+ 10%

- + 5%

f 0.10

+ 10%

10% & 5 %

f 10%

+ 5 % 7

- + 5% + 5 %


I l~o ta l 1.0- lOOOmg/l Hardness (as ~APHA 21 st EDN. 2005

Chapter 2 ~ Na) Sodium Absorbing Raio

I

Sulphate (as sod

Above 500 mg/l

0.1 - 10 1 Above 10

2 - 100.0 mg/l

Above 100 mg/l

(3500-Na-B)

By calculation

APHA 21 st EDN. 2005 (4500-S04-E) pp

CaC03) Total Nitrogen (as


- + 5% + l o %

- + 5%

+ 5 %

+ 2% -

T.S.S

Temperature

TotalDissolve dSolids

- N)

Turbidity

Zinc (as Zn)

APHA 21 st EDN. 2005 2.0 - 1000 mg/l

(2540 D) Above 1000 mgA APHA 21st EDN. 2005 (2550 B)

APHA 21st EDN. 2005 10 - 250 mg~l (2540C) Above 250 mg/l

(2340C) APHA 21st EDN. 2005 (4500N ORG B, 4500 NO3 E)

APHA 2 1 st EDN. 2005 (2 130 B)

APHA 21st EDN. 2005 (3 1 1 1B)

Above 1000 mg/l

1 - 100 mgA

- + 10%

+ 20%

Above 100 mg/l 0.5 - 10 NTU 11 -40NTU

41 - 100NTU 0.02 - 10.0 mg/l Above 10 mg/l

- + 10% + 0.2 NTU - + 0.5 NTU - + 1.0 NTU

+ 5 % - + 5%

CHAPTER 3.0

COMPLIANCE STATUS AND

MONITORING

3.1 Compliance Requirements

3.2 Present Compliance Status

3.3 World Bank Requirements

3.4 Ambient Air Quality Compliance

3.5 Monitoring

3.6 Stack Emission

3.7 ESP Efficiency

3.8 Ambient Air Quality

3.9 Liquid Effluent

3.10 Surface Water Quality

3.11 Ground Water Quality

3.12 Noise

3.13 Soil

3.14 Mercury in Environment

3.15 Issues in Monitoring

3.1 Compliance Requirements


To establish and operate a thermal power plant requires some permission from government statutory authorities. The operating unit needs to maintain some specific environmental standards to continue its operation. There are some legal requirements to comply with these standards too. Besides, as this study is for R& M for Unit 5 with the financial assistance from World Bank, the environmental guidelines of World Bank are also to be considered for the future scenarios.

Chapter 3

The operating plants require consent to operate from State Pollution Control Board under Section 25 & 26 of Water (Prevention and Control of Pollution) Act, 1974 and Section 21 of Air (Prevention and Control of Pollution) Act, 1981. Bandel TPS has regularly renewed "Consent to Operate" for the past years.

The latest compliance requirement as for the period 1.04.2006 - 31.03.2008 is discussed below. It may be mentioned that compliance for a number of parameters have been given for all the five (5) units combined.

Consent for water consumption quantity for the total power plant is given on the basis of expected power generation. Similarly the wastewater quantity is also considered theoretically. Table 3.1, Table 3.2 and Table 3.3.

Table 3.1 Consent Requirement for Daily Water Consumption for 2006-08

I Industrial cooling, Boiler feed water I Quantity (m3/day)

170035 1

Table 3.2

Processing whereby water gets polluted and the pollutants are easily biodegradable

10560

SGS

Consent Requirement for Daily discharge of effluent - Quantity and Sink


No. of Outfalls P

Quantity (m3/day) Sink

Source : WBPCB Consent to Operate

Industrial effluent 3

7 River Hooghly

Township Sewage 1

Mixed effluent

6600 Used for Irrigation

Table 3.3

llDCL

Consent Requirement for Effluent Discharge Quality* I Cooling Water ( Neutralisation I Ash pond outlet / Township


Chapter 3

pp

PH Temperature O C * *

10 "C Suspended Solids mg/l 100 100 100

**For Power plants set up before 1 June, 1999; EPA Notification GSR 7, dated 22 December 1998

Stack emission

Particulate matter - 150 mg/ ~m~ for all the stacks

Outlet 6.5 - 8.5 Not more than

Oil & Grease mgA Ron moll --- ---w - I I I , I""

To follow the action plan (for zero-water discharge) and submit the implementation plan of arrangement of recirculation of decanted water of ash pond within 12.02.2007.

COD mg/l I

3.2 Present Compliance Status

Pit outlet 6.5 - 8.5

10

1 250

Compliance to the requirements of WBPCB is checked based on the Environmental Statements of 2005-06 and 2004-05 presented to WBPCB and all the different monitoring camed out by BTPS through different laboratories authorised by WBPCB and also directly camed out by WBPCB. All monitoring data are given in Annexure 1.

*EPA Notification S.O. 844(E) dated 19 November 1996

Daily Water Consumption

6.5 - 8.5

110

At present there is no arrangement to measure water withdrawal or consumption at the plant. Compliance is achieved based on theoretical assumption based on the quantum of power generation

Sewage 5.5 - 9.0

There are two sources of water withdrawal, a) from the river Hooghly and b) from ground. The major water requirement for once-through cooling purposes is taken from the river Hooghly and which ultimately is disposed back to the river after heat- exchange. A portion of the cooling water is used for ash transportation. The amount withdrawn from the river is a theoretical assumption based on the quantum of power generation. Ground water is withdrawn by pumping and the water is mostly used for

20 20 i nn

SGS SGS India Private Limited 3 1

plant process and human uses. There is also no meter for measuring water withdrawal. Pumping hours are recorded and the water withdrawal is based on assumption of pumping capacity.

-

Table 3.4 Consent Status for

Daily Water Consumption 1 T Y P ~ I Compliance Requirement ( Consumed in I


Chapter 3

. .

(m3/day) 1 2005-06*

1 water Processing whereby water gets polluted and the pollutants are

I I

* Environmental Statement 2005-06 submitted to WBPCB

Industrial cooling, Boiler feed 1 170035 1 1 1 182845

easily biodegradable

Daily discharge of effluent - Quantity and Sink

10560

Domestic

As discussed before, there is no arrangement to measure water withdrawal and its consumption in different units. Similarly there is no metering of quantity of discharge from different sources as mentioned in the compliance requirement. The quantity generally provided in environmental statements are based on theoretical assumptions.

8884

1700 1 1700

However the effluents are discharged to the respective sinks as mentioned in Sec 3.2.2. But besides these three (3) outlets for industrial effluents, there are further two (more) outlets which are not reported. The position of all the outlets from the plant meeting the Hooghly River is shown in the Figure 3.1


* Environmental Statement 2005-06 submitted to WBPCB ** Flow partly mixed with Ash pond water



Effluent Discharge Quality

The quality of effluent discharge is monitored in the plant by two separate agencies. One set of monthly monitoring is conducted by West Bengal Pollution Control Board directly. BTPS also cames out monthly monitoring by a WBPCB-approved laboratory. The compliance status on environmental issues are given below


Effluent Discharge Quality Cooling Water Outlet

I WBPCB* BTPS**

(April 2005 - March 2007)

** Suspended Solids was measured which crossed the limit of 100 mgll often because the inlet cooling water from the river had similar higher suspended solids.

(March 2005 - April 2007) PH

26 Number of samples

Percent compliance 1 100% 1 100% ( 100%

PH Temperature Difference

100% 1 100%

Temperature Difference

23

** SS, O&G not measured

Neutralisation Pit outlet

violating compliance Percent compliance 1 100% 1 100% 1 100% 1 100% 1 100% 1 100%

0 Number of samples I 0

WBPCB

Number of samples Number of samples

7

BTPS

0

Ash pond outlet

violating compliance Percent compliance 1 87%* 1 100% 1 100% 1 100% 1 100% 1 100%

26

(March 2005 - March 2007)

WBPCB

Number of samples Number of samples

* pH vdue crossed the limit thrice but highest was 8.66 only. It may be noted that the river water used

13 0

(March 2005 - April 2007)

BTPS

has a high pH and ranges between 7.8 - 8.9. So this violation is not significant.

0

PH 26 0

O&G 4 0

PH 6 0

r SGS India Private Limited

TSS 5 0

(April 2005 - March 2007)

TS S 26 0

(March 2005 - April 2007)

O&G 26 0

O&G 22 0

PH 23 3*

O&G 26 0

PH 26 0

TSS 23 0

TSS 26 0

Ash Pond O\~rflow March 05 - April 07 9 100

8 90 7 80

Chapter 3 -

CW Temperature


Township Sewage

The results show that there is a total compliance for Cooling Water Outlet. It is to be noted that all the 7 results of CW outlet by WBPCB have shown temperature difference of 0.5"C only. It has been reported that they collected water near the confluence of the river and CW canal. The measurements done by BTPS shows

WBPCB BTPS


temperature difference of 4-9°C with the inlet river water and CW channel outlet on the canal.

llDCL

Neutralisation pit outlet and Ash pond outlet The results show total compliance.

The above results show that BTPS is having almost total compliance in respect to effluent discharge quality.


It may be noted that BOD and COD values of effluent coming out of sewage pumping station is quite low, possibly due to septic tanks and dilution by other wastewater. STP design needs to take this into consideration

Chapter 3

Stack Emission

Similar to liquid effluent monitoring, emission qualities for the stacks of all five units have been monitored by WBPCB independently (done by some laboratories employed by WBPCB) and also by BTPS by a WBPCB-approved laboratories. While WBPCB has carried out monitoring quarterly (once every 3 month), BTPS has done the monitoring monthly. Unit-5 (210 MW) is not operating for nearly a year, therefore its recent data are not available. Only particulate matter concentration has been considered for compliance.

The compliance status are given below

Table 3.7 Consent Status for Stack Emission

I

The results show almost total compliance for stack emission. However it may be noted (ref Sec 4.3) that for Unit 1 to 4, the monitoring results during the study reported repeated violations.

WBPCB

Number of samples Number of samples violating compliance Percent compliance

Additional condition

BTPS

BTPS has employed two consultant groups to prepare a plan for recirculation of decanted ash water and attain zero-discharge. However this process is still ongoing

(March 2904 - March 2007) Unit 1

10

0

100%

(February 2005 - April 2007)

%G$ SGS India Private Limited

Unit 1

25

0

100%

35

Unit 2 10

1

90%

Unit 2

23

0

100%

Unit 3

8

0

100%

Unit 3 23

1

95%

Unit 4

2

0

100%

Unit 5 8

1

88%

Unit 4

18

0

100%

Unit 5

10

0

100%

and nothing concrete has been achieved. A Detailed Project Report for Effluent treatment and disposaVrecycle system has been prepared. Only some preliminary civil work at the site for construction of Sewage Treatment Plant has been started.

Issues:

Chapter 3

.IMEL

Though on paper the compliance status seems optimistic however the real scenario can be quite different. Firstly as there is no measurement of any water or wastewater flow so all the given data were theoretical. Stack emission monitoring were only measured when the units are running in good condition. It may also be pointed out that while the monitoring results by different laboratories remained similar for the parameters related to the compliance status, there have been significant variation in the monitoring results for the other parameters not related to compliance status.


Beisdes, the zero-discharge requirement by WBPCB has not yet been achieved

The overall status of compliance and the issues to be addressed are summarised in Table 3.8

3.3 World Bank Requirements and Potential areas of difference

Table 3.8 Overall Consent Status

The present study for renovation and modernisation (R&M) of BTPS is being done as a World Bank assignment. It is therefore required to enquire about the environmental requirements as per World Bank norms. These norms are given in Pollution Prevention and Abatement Handbook (PPAH), 1998 published by World Bank.

Topic Daily Water Consumption Daily discharge of effluent - Quantity and Sink Effluent Discharge Quality

Stack Emission

Additional condition

Critical Environmental Requirement for Rehabilitation of Thermal Power Plants as per World Bank Bank's Pollution Prevention and Abatement Handbook are:

Compliance Status Not complied

Notcomplied

Complied

Complied

Not complied

Issues No measuring system exists to check compliance No measuring system exists to check compliance Number of Outfalls more than 3 CW outlet TSS was not always within the limit of 100 mg/l but then inlet water had higher TSS Monitoring during the present study did not match with the results for Unit 2-4 Compliance procedure under process. Needs to be done urgently

SGS India Private Limited %

36

a) 'It is neither possible nor desirable to attempt to prescribe specific environmental guidelines' (pp 427)

b) 'It is recommended that an environmental audit be undertaken in almost all cases' (pp 427)

c) 'Major rehabilitations that imply a substantial extension (10 years or more) of the expected operating life of the plant . . . . . . . . . The plant will normally be expected to meet the basic guidelines that apply to the new thermal power plants for emissions of particulates, nitrogen oxides, wastewater discharges and solid wastes.'(pp 427)

llOCL

Potential areas of difference between the standards of WBPCBMOEF with World Bank needs to be expressed to plan for setting future environmental goals for the power plant. The major differences are given below. However it needs to be decided whether more advanced standards can be taken up or not. As the focussed power station Unit 5 is 25 years old, it may not be appropriate to specify stricter environmental standard for renovation

Table 3.9 shows the difference in Emission Standards of WB and MOEF


Chapter 3

Liauid Effluent

Table 3.9 Difference in Emission Standards of WB and MOEF

Stack Emission

-- ~-~ ----- ~

Parameter I MOEF, India I World Bank nH 1 6 - 8.5 / 6-9

World Bank

Particulates PM

50 - 100 mg/Nm3

Sulphur dioxide

0.2 metric tons per day 12000 m g / ~ m ~

3

. .

Suspended Solids Oil & Grease

I Iron (total) I 1.0 mdl I 1.0 md l 1

Nitrogen Oxides 750 mg/Nm3 None

Total residual chlorine Chromium (total) Co pp er (total)

\ - - ~- -, u " Zinc I 1.0 mg/l I 1.0 mg/l Temperature 1 Not more than S°C I Not more than 3°C 1

-

100 mg/l 20 mg/l

I from intake* I from intake * For new plants

. .

50 mgA 10 mg/l

0.5 mg/l 0.2 mg/l 1 .O mg/l

3.4 Ambient Air Quality Compliance

0.2 mg/l 0.5 mg/l 0.5 mg/l

There is as such no compliance requirement for ambient air quality for BTPS. However ambient air quality around the plant is routinely monitored to check the ambient air quality comparing it with the national standards to have an idea of impact on air quality by the plant. Though for annual average a minimum of 104 (twice a week) samples are required as per National Ambient Air Quality Standard, at present

1 s(;s SGS India Private Limited

we may proceed with the available data. During 2006-07 ambient air quality for the parameters in respect of SPM, PM-10 (RPMO, SO2 and NOx have been monitored at three (3) locations around and inside the plant. The locations were Gate No. 3, Gate No. 4 and at CHP plant. The annual average for the period and comparison with different standards are given in Table 3.10.

Table 3.10 Annual Ambient Air Quality (April 2006-2007)

Chapter 3 -

It can be seen that in respect to Industrial standard, BTPS is achieving the target but its SPM and RPM concentration in ambient air is quite high for residential standards. As the residential areas are close to the plant, residential area standard should be the target just outside the plant. In comparison to World Bank general standard, SPM and RPM concentrations are very high.


However according to World Bank Guideline, "an airshed will be classified as moderate air quality with respect to particulates, sulphur dioxide or nitrogen dioxide if either 1 or 2 applies:

l(a) The annual mean of PMlo exceeds 100 mg/m3 for the airshed (160 mg/m3 for TSP); (b) the annual mean of sulphur dioxide exceeds 100 mg/m3 for the airshed; or (c) the annual mean of nitrogen dioxide exceeds 200 mg/m3 for the airshed; 2. The 95" percentile of 24 hour mean values of PMlo, sulphur dioxide and nitrogen dioxide for the airshed for a period of a year exceeds 150 mg/m3 for the airshed (230 mg/m3 for TSP)." (PPAH, pp 417) For this specific case we do not have enough data to compare 95" percentile of 24 hour mean values, so condition 1 may be considered. To compare with condition 1, the results at CHP which is inside the plant, can be left out. The air quality at other two places just at the boundary of the plant shows that the levels of the pollutants are below the levels mentioned in condition 1. So the area having these power plant units still does not fall into poor air quality area and can be considered moderate air quality. For such area, WB guideline allows maximum emission limits for power plants below 500 MW (PPAH, pp 417).


3.5 Monitoring

wuooL

Monitoring of environmental parameters is the best option to check the present compliance status and ensure better environmental performance in future. Before we have discussed the compliance status based on past measurements but it was decided to monitor the important environmental parameters during the present due diligence study. The monitoring plans for the study and the monitoring protocols have been discussed in Sec 2.4 and Sec 2.5 respectively.

Details of all monitoring results done during this study are given in Annexure 2.


3.6 Stack Emission

Chapter 3

For any coal-fired thermal power plant, a major source of emission of particulates and other gases is the boiler stack. As per the monitoring plan (ref Sec 2.4) emission from all the stacks of the running units were measured in accordance with the monitoring protocols. Stack emission measurements were carried out 22, 23 & 24 August 2007. As this study is primarily focussed on the R&M of the fifth unit (210 MW) of the Plant, so the stack emission results for the Unit 5 are considered first.

Stack Emission from Unit 5

The results of the monitoring is given below in Table 3.11

The results show that emission from the Unit 5 (210 MW) meets the WBPCB standard for Particulates and World Bank Standard for SO:! and NOx. But to meet the ..-

World Bank Standard for particulates, the emission control needs to be more

Table 3.11 Stack Emission Results for Unit 5

Unit 5 - 210 MW


Load ESP Fields in Service

SO2

NOx

PM

Hg * World Bank Standard #West Bengal Pollution Control Board (WBPCB) Standard

MW

m g / ~ m 3

mg/Nm3

mg/Nm3

p g / ~ m 3

Compliance Requirement

2000*

750*

150# SO* N A

Test 3

190 12of 12

324

529

53

7.14

Test 1

193 12 of 12

435

75 1

101

2.8 1

Test 2

191 12 of 12

499

649

100

4.74

stringent. However for such old plant a more realistic limit of 100 mg/Nm3 will be practical

Monitoring results camed out by other agencies appointed by BTPS before shows (Ref Annexure 1) that emission from the stack of Unit 5 mostly meet the prescribed standard for particulate matters.

Chapter 3

*llOQ

The emission results measured by BTPS varied between 21.83 to 139.12 mg/Nm3, the median value being 69.58 m m3. Emission results measured by WBPCB has one high value of 343.7 mg/NmpThe other values ranged between 35.9 to 95.4, the median value being 54.5 mgmm3. The median of the results monitoring during the study is 100 mg/Nm3. The details of the emission results measured by WBPCB and BTPS are given in Annexure 1.


Stack Emission From Unit 1 -4

At the same time Emission concentration and ESP studies were carried out for Unit 1, Unit 3 and Unit 4. Unit 2 was out of operation at that time. It may be mentioned that these units are quite old and its stack heights are low, 60 m high.

The results (ref Table 4.6) show that Unit 4 often had always high particulate emission level as half of its fields in ESP are not functioning. Unit 3 also violated the standard. There was no problem with emission of SO2 and NOx. The high emission level in these units are often also linked with operation problem with combustion generating high amount of particulates. There has been 20 Shutdowns involving Unit 1 to 4 in last 6 months of January - June 2007.

Table 3.12 Emission from Unit 1-4

* World Bank Standard #West Bengal Pollution Control Board (WBPCB) Standard

The results clearly show that though the different previous reports showed that the units 1-4 are complying the emission standards, our monitoring shows that except Unit 1, other two units are not complying at all. As these units are not for R&M programme, further analysis is not attempted.


3.7 ESP Efficiency and Emission Quality

V I D C L

Unit 5

Electrostatic Precipitator (ESP) is the main device to control emission of the particulates to the environment from burning of the fuel. The ESP for the unit V (210 MW) was installed at a time when there was no emission standard for the power plants. The ESP of Unit NO. 5 is of BHEL make and has got 12 fields. The unit -V of BTPS was commissioned during 1982 with a designed emission of the ESP as 1020 mg/Nm3 in full load considering inlet dust concentration as 51,000 mg/ ~ m ~ . The designed efficiency was 98%. Since the efficiency of the ESP of Unit-V could not be bettered, Ammonia Flue gas conditioning plant has been installed at Unit - V to bring down the level of emission below 150 mg/Nm3. Ammonia injection for controlling particulate matters has been successfully implemented in Indian power plants. Chemithon Engineers Pvt. Ltd. (CEPL), a joint venture with Chemithon Enterprises Inc., USA, world leaders in the environmental equipments has successfully commissioned such systems adopting a technology from Heavy Water Board (HWB), a Government of India organization. The said plant is now under operation and performing successfully since July 2004. At present it has been found by the project authorities that injection of ammonia is often required to ensure the prescribed standard of 150 mg/Nm3. To verify the ESP efficiency the tests were conducted both during ammonia injection and without ammonia injection.


Gas inlet from the boiler is distributed in four (4) lines entering the ESP and also comes out similarly from the ESP. Due to the locational problem for monitoring, inlet and outlet emission and gas flow were measured at four inlets and outlets. The ESP efficiency results and the emission level for both conditions are given below in Table 3.13 and Table 3.14

Chapter 3

The results show that though the ESP efficiency increases significantly due to ammonia injection, from 0.09% to 0.76%. This increase is sufficient to have emission concentration gets reduced significantly to come down much below the present permissible level.

While the emission level without ammonia injection remained between 143 mg/Nm3 to 222.25 mg/Nm3, the emission level after ammonia injection was reduced between 72 to 107 mg/Nm3.

- SGS India Private Limited

Table 3.13 ESP Efficiency (%) of Unit V

Test 3

99.42 99.5 1

Test 2 99.17 99.68

Without NH3 With NH3

Test 1

98.97 99.73

Table 3.14

- Particulate Emission Concentration - Unit 5


Chapter 3

(mg / ~m~ )

Particulate Emission Concentration - Unit 5

' 250 2 s S 200 Q - a $ 2 150 Q z a. 6 g 100 -With NH3 E 0 .-

50 CI

5 E 0

0" Test 1 Test 2 Test 3

Test 1

Without NH3 With NH3

Unit 1-4

While testing of ESP efficiency it was found that ESP efficiencies (ref Table 3.14) varied between 97.66 to 99.4. It may be mentioned that these ESPs are of old design when the efficiency was designed to have particulate emission within 350 mglNm3. These tests found ( ref Table 3.15) that Unit 3 and Unit 4 are emitting particulates at higher level and ESP efficiencies are also low between 96.92 to 98.34. Unit 3 and Unit 4 also failed to meet the compliance standard for WBPCB. This is in contrast with the general compliance scenario of the plant

Test 2

225.25 72

Test 3 1 160

87.25

Table 3.15 ESP efficiency (76) of Unit 1 to 4

Test I Unit- 1 I Unit - 3 Unit - 4

143 - 107

1 2

S@S SGS India Private Limited

99.35 99.46

42

Avg I 99.405

98.4 96.92

97.66 99.02

97.66 98.34

Table 3.16 Emission Concentration of Unit 1 to 4

Unit - 1 Unit - 3 Unit - 4

1105

-

1 Avg 1 96 1 698 1 375.5 1

Particulate Emission Concentration - Unit 1,3 & 4

i

B 1200

Z 0, 1000 c. a - a 800 .g -'E

p" 5 600 -m- Unit - 3 -z c 400 0 .- L.

2 200 L.

e 8 e 0 6 Test 1 Test 2 A 3


3.8 Ambient Air Quality

Chapter 3

Ambient air quality monitoring was canied out at 5 places. Locations have been selected based on airshed region and sensitivity. The emission dispersion from the Bandel TPS have two different components as the stack heights are different. While 210 MW unit has a stack of 120 m high, the stacks of other four units are only 60 m. So the air shed region will be different. The locations at administrative building at the plant was selected to present an overall scenario at the plant and at CHP to present the scenario inside the dust prone area of the plant. The monitoring location at the local college was selected considering it as a sensitive place. One monitoring station was located at BTPS township considering it as sensitive place. The Players Club situated at the locality called Refaitpur is close to the plant and from where there is strong opposition of dust pollution emanating from the plant.

Table 3.17 shows the results on ambient air quality. The results show a very clear ambient condition, even inside the plant area. However this being the rainy season (though there was no rainfall during monitoring days), air quality remains good due to washing of the pollutants by rainfall. These results should not be considered for any decision making.

qG% SGS India Private Limited %+

43

Table 3.17

Chapter 3 - Comprehensive Environmental Audit and Due Diligence Assessment of the Bandel Thermal Power Plant

Parameters

SO2

NO2

SPM

PM- 10 (RPM)

Hg

Ambient Air Quality on Day 1 (22-23 August 2007)

250

200 c o -m-Adrn Build

150 E CI

College c $ 100 -----E--.- Players Club c +Township

50 -Residential Std.

0

N02, pgIrn3 SPM, pg/rn3 PM-10 (RPM),

pg/m3

Unit

pg/m3

pg/m3

Elm3

pg/m3

pg/m3

Parameters

SO2

NO2

SPM

PM- 10 (RPM)

Hg

Unit

pg/m3

pg/m3

pg/m3

pg/m3

pg/m3

Day 3 (24.08.2007 - 25.08.2007)


Day 2 (23.08.2007 - 24.08.2007)

CHP

<4

12

94

43

<0.1

44

Township

<4

19

170

117

<o. 1

CHP

<4

9

112

47

<0.1

Adm Build

<4

12

85

28

<o. 1

Adm Build

<4

15

82

27

<o. 1

College

<4

4

126

45

<o. 1

College

<4

4

8 1

19

<o. 1

Players Club

<4

12

9 1

27

<o. 1

Players Club

<4

27

95

31

<o. 1

Township

<4

11

105

55

<o. 1


-

-m-Adm Build

College

.---K-- Players Club

1 ++Township

-Residential Std. ~ 1


N02, pgIm3 SPM, pgIm3 PM-10 (RPM),

pg/m3

Chapter 3


N02, pgIm3 SPM, pgIm3 PM-10 (RPM), IJgIm3

3.9 Liquid Effluent

Process Effluent

Thermal power plant does not have any direct process effluent. However wastewater is generated from number of supporting operations. In case of Bandel TPS, following are the major wastewater sources.

a) DM Plant Neutralisation pit - Wastewater from DM operation are neutralised and then disposed.

'$[is SGS India Private Limited

b) Ash pond outlet - Ash from Unit 5 is hydraulically camed to the ash pond for settling. The ovefflow from the ash pond can be considered as an effluent from power production activities

Table 3.18 presents the effluent quality. These parameters are mentioned in CPCB and World Bank standards for the thermal power plant effluent. Besides, phosphate and mercury have been monitored. It shows that the effluents meet all the relevant standards except a little higher particulates level than WB standard (50mgll) in ash pond outlet. .

Chapter 3 -

Table 3.18 Process Effluent Quality monitored during the study

I


* World Bank Standard #West Bengal Pollution Control Board (WBPCB) Standard ** World Bank Standard General Guideline

Treated Process EMuent

There is no as such wastewater treatment in the plant. The wastewater streams which are ultimately disposed to the Hugli river are considered as treated process effluent. WBPCB allows three outfalls to the river Hugli for CW outlet, DM Plant neutralisation pit outlet and Ash pond water. Township sewage is to be used for imgation.

However as mentioned before Sec 3.2 that there are actually 5 outfalls. During the monitoring time there was no flow in one outfall (not mentioned to WBPCB).


Table 3.19 shows the final effluent qualities before disposal monitored during the study. It shows that the suspended solids concentrations in the effluent streams are often higher than the permissible limit. This is because that the effluent streams are mixed with different unidentified and untreated wastewater from the plant. In case of ash water streams, a local drain falls into it and as it the stream goes through an open channel by the side of a public road, there is little surveillance on it. Besides concentration of iron is very high in the Neutralisation stream outlet. Temperature difference of CW with the main river was maximum of 6.5"C.

*.cocL

Table 3.19

Final Emuent Quality Before Disposal

* Temperature difference with main river 7.0°C ** Temperature difference with main river 4.9"C *** Temperature difference with main river 7.8OC


lay 3 (24.08.2007) Ash Neutrali Pump

Pond & sation Cooling, Townshi Pit Lab

p Outfall - Drain Sewage etc. Combin Outfall -

ed Outfall -

7.24 7.23 7.34

33.4 30.9 28.9

<0.10 <0.10 <0.10

Chapter 3

Monitoring of Cooling Water Discharge in the River

It may be mentioned that the cooling water temperature is being monitored at the point of cooling water outfall in the disposal channel leading to the river. However the warm cooling water is actually mixing with the river Hugli where the disposal channel meets the river. As monitoring water temperature there is little difficult as


there is no direct accessibility to that point. At present only boat has to be used to reach the confluence of the CW channel and the river. In fact the water temperature difference is only important to compare with the statutory requirement.

During the present study, the water temperature was monitored at the confluence and also at the river mixing zone. The monitoring locations are shown schematically below.

Chapter 3

.mcc

Pont 1 - Inlet Point 2 - CW outfall on canal Point 3 - Mixing point with river Point 4 - 100 m Downstream


Intake Turbulence Zone Mixing Zone

Condenser Canal River

The monitoring results are given below

Water Temperature (OC) At Different Monitoring Locations I Date of I Point I I Point 2 1 Point 3 I point4 1

Monitoring 22.08.2007 23.08.2007 24.08.2007 17.01.2008

Date of Monitoring

22.08.2007 23.08.2007 24.08.2007 17.01.2008

30.4 31.5 29.5 23.7


Temp Diff Between Point 1 - Point 2

7.0 4.9 7.3 4.7

48

37.4 36.4 36.8 28.4


2.4 0.8 3.0 2.7

32.8 32.3 32.5 26.4


0.5 0.3 1.9 -0.1

30.9 31.8 3 1.4 23.6

Water Temperature at Different Monitoring Locations

38

0 O 34 C .- g -m- 23.08.2007 a 30

24.08.2007

26 --*- 1 7.01.2008

+ 22

Point 1 Point 2 Point 3 Point 4

-

Temparature Differences

Point 1 - Point 2

-Temp Diff Between Point 1 - Point 3


Date of Measurement

The above results show that the water temperature gets substantially reduced while meeting the river and temperature difference remains within 3 ' ~ .


Sewage Effluent

Chapter 3

There is no sewage treatment plant in BTPS township. The domestic sewage generated in the plant and also mixed with other service water in the township is collected in a tank and pumped out without any treatment. This wastewater is taken inside the agricultural fields through a number of paved open channels as this wastewater is used in agriculture. A part of the unused water mixes with ash pond water for ultimate disposal. The results are given in Table 3.20.


Sewage Effluent Quality

300 250 200

0) 150

>" 100 -BOD, mg / I

50 COD, mg / l

0 Day 1 Day 2 Day 3

(22.08.2007) - (23.08.2007) (24.08.2007)

Date of Sampling

Chapter 3 - Table 3.20

Sewage Effluent Quality

3.10 Surface Water Quality


The major surface water which can be impacted due to disposal of the wastewater is the river Hugli. A detailed water quality study was carried out both upstream and downstream of the river. The pond near ash pond is another surface water which was monitored to find out any impact of the nearby ash pond. Table 3.21 shows the results. There is no significant impact on the surface water quality.

Parameters Suspended Solids

BOD

COD Oil & Grease

PH


Day 1 (22.08.2007) -

18

44.4

264.3

BDL (DL - 2.0)

7.55

Unit mg/l

mgfl

mgfl

mgfl

Day 2 (23.08.2007)

20

36.3

235.2

BDL (DL - 2.0)

7.59

Day 3 (24.08.2007)

18

26.4

171.4

BDL (DL - 2.0)

7.46


Table 3.21 Surface Water Quality

S%;s SGS India Private Limited

Day 1 (22.08.2007) Day 2 (23.08.2007) Day 3 (24.08.2007) River - River - Pond near River - River - Pond near River - River - Pond near

Downstrea Upstream Ash Pond Downstrea Upstream Ash Pond Downstrea Upstream Ash Pond m 50 m. 100 m. Towards m 50 m. 100 m. Towards m 50 m. 100 m. Towards from last from first River - from last from last River from last from last River -

outfall - outfall - outfall outfall

Alkalinity Ammonia (as NH3 -

Free) B.0.D @ 27°C for 3

days Barium (as

mgA <1.0 <1.0 <1.0 <1.0 4 . 0 <1.0 <1.0 <1.0 <1.0

mg/l

mg/l

mgA

90.38

0.4

4.19

92.43

0.4

3.81

188.97

0.4

3.75

107.84

0.4

5.17

97.57

2

5.83

179.73

0.4

4.13

87.3

4.8

4.83

82.16

2

2.25

87.3

0.2

4.13

S6;S SGS India Private Limited

Chapter 3

-L


- -

Surface Water Quality - Some Major Parameters


50

45

40

35 m. from last outfall 3 30 2 25 River - Upstream I00 m.

2 20 from f~rst outfall -

15

10

5

0

Chapter 3

B.0.D @ COD, mg/I Calcium D i s s o l ~ d pH 27% for 3 (as Ca), Oxygen, days, mgll mg/l mg/l

3.11 Ground Water Quality

The water quality from the tube well near the ash pond was monitored. Table 3.22 shows the results. There is no observed impact on the ground water quality.


Table 3.22 Ground Water Quality

Chapter 3

YMCL



Turbidity

Zinc (as Zn)

NTU

mgll

2.1

0.07

c0.5

0.1

2.8

0.08

3.12 Noise

- Source Noise

Noise level was monitored for 8 hours at a distance of 3 m from the turbo-generators in the plant. Table 3.23 shows the results. The results show that the level was above 90 dBA but as people do not work there continuously, there is no imminent danger.


Table 3.23

Generator Noise Level Leq in @(A)

Chapter 3

Ambient Noise

Day 1 (22.08.2007)

Day 2 (23.08.2007)

Day 3 (24.08.2007)

Noise level was monitored at plant, canteen, residential and commercial areas. Except during start ups, the power plant noise do not affect the people outside. Noise level monitoring results are given below in Table 3.24.

Table 3.24 Ambient Noise Level in dB(A)

Generator # 1 96.77

92.99

96.62

Generator # 3 99.03

96.72

98.61


Generator # 4 98.49

98.42

98.22

Generator # 5 92.99

98.65

92.3

Comprehensive Environmental Audit and Due Diligence Assessment of the Bandel Thermal Power Plant I Carpurl I

Comparing the monitored results with the Ambient Noise Level Standard given below, it may be observed that Canteen and market areas have higher noise levels. Noise level at Players Club, a residential area is also on higher side. However this is the general noise trend in Indian situation.

Ambient Noise Level Standard

Place

3.13 Soil

Desired Noise Level (Leq)*

Sensitive Area (e.g School)

Residential Area

Commercial Area

Industrial Area

Soil parameters of the land near the ash pond and far from the ash pond were monitored to investigate any accumulation of heavy metals from ash pond. The results

. are given in Table 3.25. The results do not indicate any accumulation of heavy metals or mercury near ash pond site.

Table 3.25

Soil Quality

Ref: EPA Notification [GSR 1063(E) dt 26.12.19891

Day

50 dBA

55 dBA

65 dBA

75 dBA


Night

40 dBA

45 dBA

55 dBA

70 dBA

3.14 Mercury in Environment

-

Mercury (Hg) is not included in the list of pollutants to be monitored for Thermal Power Plants generally. There is no Indian regulation on that and World Bank also has no regulation on mercury (ref: PPAH). However there has been recent concern on mercury emission to atmosphere in general and particularly from coal-fired power plants. It was therefore decided to monitor to find out mercury emission and distribution from thermal power plant

To find out the mercury from source and in final solid waste, mercury content in coal and ash were measured along with other properties.


Mercury as found in the monitoring is given below

Chapter 3

* Average of three results (ref: table 3.1 1)

As ash collected for monitoring was not from the same coal which was being monitored, the mass balance is done on average coal consumption and ash content.

Hg 0.09 ~0 .05 4.897

Source Coal Ash Stack emission - Unit 5 *

U b P% 3. SGS India Private Limited

Unit mg/kg mg/kg jqg/Nm3

Considering 595 kg/MWh coal consumption (ref Sec 6.2) for Unit 5, Coal consumption for 210 MW = 124950 kg/hr Mercury in coal = 1 1.2455 g d h r Stack emission = 1090400 ~ m ~ / h r (Average measured value = 986551 ~ m ~ / h r at 190 MW load) Mercury in gaseous emission = 5.3397 g d h r Considering 5% mercury in particulates = 0.562 g d h r Expected mercury in ash = 5.3438 g d h r Considering 30% ash content, Total ash = 37485 kglhr Expected mercury concentration in ash = 0.142 mgkg Measured mercury concentration in ash = Less than 0.05 mgkg So there is a significant discrepancy in mass balance of mercury.

It may be concluded that for mercury balance a more detailed study is required with larger number of samples.

Chapter 3

-I.

3.15 Issues in Monitoring

Overall observations of the monitoring results highlight that


a) Nearly all the effluents are meeting the compliance standards except the emission from the stacks of Unit 3 and Unit 4 (Unit 2 was out of operation).

b) Ambient noise level was high but that is typical for Indian scenario c) No accumulation of heavy metals in effluent or soil was observed d) Though mercury balance could not be done, mercury level in local water or

soil was not insignificant


4.1 Introduction

4.2 Wastewater Management

4.3 Stack Emission

4.4 Fugitive Emission

4.5 Solid Waste

4.6 Hazardous Waste

4.7 Housekeeping


m

4.1 Introduction

The operation of a thermal power generates different types of wastes. These are liquid wastes, gaseous wastes and solid wastes from different units related to generation of power and from different utilities operation. Different sources of pollution are managed in different ways to meet the regulatory environmental compliance. This chapter discusses the waste generation and the control measures adopted in the plant.

4.2 Wastewater Management

The major sources of liquid effluents in the plant are:

Cooling Water discharge Boiler blow down Oil handling area run off Plant services waste water (surface drains) DM Plant regeneration waste Canteen wastewater Laboratory wastewater Bottom ash trench Run off from coal stock yard area Ash pond water Plant sewage and Township sewage

As has been mentioned before that there is no measurement of wastewater flow in the plant. Overall wastewater quantity is derived on the basis of overall power generation. Also as will be discussed later that the wastewater streams are mixed with each other and all the outfalls to the river are not accounted for. The overall per day wastewater generation from the plant is given in Table 4.1.


YIDCL

The wastewater management in the plant is discussed below in details. Figure 4.1 shows the management steps. The details are discussed below

Table - 4.1 Wastewater Generated On Per Day Basis

For The Year 2006-2007

Cooling Water discharge, Boiler blow down, Bottom ash trench and Surface drains


No. 1. 2.

3. 4.

Unit 5 (and also other units in the plant) uses once through cooling system. In this system the cooling water from the source (river) is directly passed through condenser and the warm cooling water is disposed. In this situation if no chemical is used to control algae etc there is no chance of pollution except the rise of temperature.

Chapter 4

In the present case for Unit 5, water from the river flows into the individual pumps suction basin through trash rack, inlet gates and travelling water screen. The travelling screens arrest the floating and suspended debris from the water and bring them up where they are washed with high pressure water jets. All the pumps discharge into the common 2.2 M dia C.W. header supplying water to the twin condensers.

Nature Cooling water Ash Pond Overflow

D.M Plant Sullage Pump House

The outlet from the condenser is returned to the down streamside of river through concrete underground tunnel and discharge weir. The water through discharge falls in a short canal of about 70 m long which meets the river Hugli.

* The cooling system is designed to have a maximum temperature gradient of 10°C, and the environmental compliance of MOEF requires to maintain the same temperature difference for cooling water discharge, no control system has been adopted. As the water passes underground in the plant area, there is very little chance of natural cooling due to exposure to atmosphere. The temperature difference has been measured at the outlet where it meets the canal and the result has remained always below 10°C.

Source Plant Plant

Plant Township

SGsi SGS India Private Limited

Qty [m3 /~ay ] 846801.0 4052.0

74.0 600.0

Place Of Discharge River Hooghly River + Irrigation Hooghly

River Hooghly River Hooghly

WBPCB measurements have reported temperature difference for cooling water discharge with river water as only 0.5 OC (refer Sec 3.3).

However as described before (ref Sec 3.9), the temperature difference between the intake river water and the CW outlet at the confluence of the river remained with 3 OC.

Chapter 4 -

Issues


Boiler blow down, Bottom ash trench and some surface drains are also led to the CW trench and thus external pollution to the cooling water is introduced.

Though due to huge volume of cooling water the quality of the effluent is not affected but it needs to be avoided as it violates the compliance and goes against the principle of protecting environmental quality of the river.

DM Plant Regeneration Waste, Surface drains

Demineralisation units need regeneration periodically. Depending on inlet water quality, anionic and cationic resin beds are regenerated by acid and alkali. The wastewater from regeneration are collected in a pit. The acidic and alkaline wastewater gets partly neutralised by themselves and then neutralised by adding excess acid or alkali as required. DM plant outlet meets the desired compliance limits.

The outlet channel from neutralisation pit ultimately falls into the river Hugli.


Issues

-L

Here also other wastewater streams e.g. some surface drains from coal and oil handling areas are led to the outlet channel from neutralisation pit.

This outlet is monitored only for pH and other inorganic pollution and thus the organic pollutants are not accounted for.


Table 4.2 Waste Water Generation From Neutralizing Pit

For The Year 2006-2007

Chapter 4

Neutralizing Pint wastewater generated in the tune of 27171 KUyear and 74.44 KLIday .

Canteen wastewater, Laboratory wastewater, Auxiliary cooling water and other surface drains

All the wastewater are mixed and led to the Hugli river finally through a common channel. This outfall is not mentioned in the environmental statement and violates the compliance of number of outfalls stipulated by WBPCB.

Issues

This stream carries significant pollutant load but is not being considered. This needs to be rectified in future.

sGs SGS India Private Limited 62


Chapter4 ~ Oil handling area run off, Coal stock vard area run off

Run off from Oil handling area and Coal stockyard area is generated during rainy season. Besides, the cleaning of oil unloading area also generates oily effluent. The effluent from this area mostly contains coal particles and oil. The surface drains carrying the run offs and wastewater partly goes to neutralisation outlet as mentioned before. Most of the effluent goes to a pond called 'Tel pukur' (oil pond). This wastewater pit is at present surrounded by walls and there is no entry to the pond. The outlet from the pond goes outside the boundary of the plant under the public road and meets the nullah leading to the river Hugli. This nullah also canies the ash pond water. There is no management of this 'oil pond'. Unauthorised persons enter this pond dangerously through the outlet pipe from roadside and collects settled coal particulates.

Issues

Wastewater from Coal yard is not being managed properly. The wastewater without any treatment goes out to different outlet channels

Oil pond is not maintained and at now it in a very bad condition. This waterbody need to be renovated and properly used in wastewater management

Ash pond water

Bottom ash and fly ash of Unit 5 is taken hydraulically as slurry to the ash pond. The ash water pumps take suction from the ash water sump and supply water to the. hydro-vectors of the fly ash collecting system, to flushing water lines to bottom ash hopper and coarse ash hoppers and to the hydroejectors of the bottom ash removal system. The high velocity water canies the bottom ash slurry discharging from the grinder, to the disposal site through 2 nos. slurry transport lines. The fly ash gets mixed with water down stream of the hydro-vactor and the slurry is discharged to the disposal site via the same set of disposal lines as for the bottom as removal system.

There are two ash ponds which are outside the main plant area and separated by a village area. When one ash pond is used, the deposited ash from the other one is excavated. Each ash pond is about 750 m long and 150 m wide. The ovefflow water at the end of ash pond is disposed through a number of pipes to an outside channel. This channel goes around outside the power plant and ultimately falls in the river Hugli.

Sa SGS India Private Limited 63

A part of Township sewage is also disposed in the ash pond outlet. This ash pond nullah also receives a local drainage channel and also the outlet from the oil pond in the plant.

-

Issues

Ash pond ovefflow water is being mixed with other wastewater from outside sources and the combined flow is falling in the river Hugli. This needs to be stopped.


For zero-discharge ash pond water needs to be recycled and its viability needs to be studied.

Chapter 4

Plant sewage and Township sewage

The wastewater and sewage from all toilets in the plant is led to the respective septic tanks. The ovefflow from the tank at present is sent to the surface drains.

Township sewage from septic tanks and other wastewater from human uses are passed through screens and collected in an open lined pit. The sewage is then pumped out to a channel which ultimately meets the ash pond outlet channel. A number of lined drains from the sewage channel take the sewage into the agricultural field.

Issues

A separate Sewage Treatment Plant is being constructed for the township. However the treated water should be totally given to the farmers.

A separate arrangement to dispose the excess treated sewage water should be planned.

It is quite evident from the above discussion that there is hardly any wastewater treatment at present inside the plant. Effluent from DM plant is neutralised, plant sewage is provided intermediate treatment in the septic tanks and some settling of solids take place at 'Oil Pond'. All other wastewater streams are disposed at random, mixing each other in a convenient manner. Overall it can be said that the plant needs a comprehensive wastewater management scheme to meet the compliance.


4.3 Stack Emission

The stack attached to the boiler of Unit 5 is 120 m high. The gas produced from combustion of coal is passed through the ESP to control particulate emission.

Chapter 4

WwoCL

The present ESP has six (6) fields and is not designed to control the emission of particulates within 150 mg/Nm3 as described before To achieve the limit ammonia is injected in the gas entering the ESP which helps to increase the collection efficiency of the ESP and the emission limit is easily achieved. During this study, emission from ESP was measured without and with the injection of ammonia and it was found that the emission limit could only be achieved when ammonia is injected.


Ammonia Injection

Ammonia injection for controlling particulate matters has been successfully implemented in Indian power plants. Chemithon Engineers Pvt. Ltd. (CEPL), a joint venture with Chemithon Enterprises Inc., USA, world leaders in the environmental equipments has successfully commissioned such systems adopting a technology from Heavy Water Board (HWB), a Government of India organization. The system is working satisfactorily for Bandel TPS. Refer Sec 3.6 and Sec 3.7 for detailed test results.

A frequent problem for units burning low sulfur fuels is the appearance of a persistent stack plume. This is because the performance of Electrostatic Precipitator's is sensitive to the Physical properties of flue gas and fly ash particles. Switching to fuels of different chemical makeup changes both flue gas and ash mineral compositions. Collection efficiency tends to suffer when low sulfur fuel are fired in units. "Conditioning" the flue gas with small amount of ammonia (NH3) or Sulfur Trioxide (SO3) can reverse these adverse effects. Here in BTPS only anhydrous ammonia is used. The negatively charged particles deposited to collecting plate, which is earth end. The role of ammonia can be explained as:

i) It agglomerates the ash particle and improves the attraction towards the plates. ii) It helps to reduce the re-entrainment of separated ash particles. iii) Anhydrous Ammonia helps to contribute the negatively charged electrons with its

molecular configuration to the surrounding dust particles and ultimately helps to generate more negatively charged ions. Those negatively charged ions helps to reduce the resistivity of the dust particles and increase the conductivity of the dust particles. So the particle and increase the conductivity of the dust particles. So the particle ionized very easily which helps to deposit the particles to collecting plates and ultimately remove dust particle from the gas stream in large volume.

Issues

Whether it can steadily achieve the limit of 100 mg/Nm3 limit for particulates by World Bank

$GS SGS India Private Limited *,a 65

Any unused ammonia coming out with the gas and its impact on end product

Safe Handling of Ammonia

-

4.4 Fugitive Emission

Main source of air pollution in the plant and around is fugtive emission from different sources.


Coal Stockyard and CHP

Chapter 4

Coal stockyard area does not have any dust suppression system and becomes a source of dust pollution during dry season. There is also inadequate housekeeping, which allows dust to accumulate here and there and cause fugitive emission. CHP also lacks adequate provision for dust suppression. The construction work inside the plant also does not give much attention to the fugitive emission from construction activities.

Silos

Another source of fugitive emission comes from unloading of dry ash from ash silos. Though at present the fly ash from Unit 5 is not collected as dry ash (because of some problem in dry ash collection system), but the existing practice for Unit 1 to 4 needs to be studied for similar operation in future for Unit 5. At present ash is unloaded from the bottom of the silo into open truck. There is some arrangement for water sprinkling during unloading, but is not sufficient. This causes fugitive emission of fine dust particles. The ash deposited on the paved floor within the ash silo area bounded by high walls, is cleaned by water. The ash water is passed through a series of baffles to settle the ash. But the ash dispersed to the plant area and towards the roadside causes fugitive emission. Besides, this emission is an important source of occupational health for the workers working in that zone.

Ash Pond

Another source of fugitive emission is the ash pond. The ash pond dykes are yet to be properly vegetated with trees with broad leaves and larger canopy. Besides the roads leading to the ash pond are unpaved and full of ash which spreads in the air. Trucks carrying ash from the pond are also sometimes not properly covered and lot of ash flies to get disposed at the area around.

Issues

Coal handling and stockyard area does not have any dust suppression system

Housekeeping is not satisfactory. Internal roads are not well maintained.


There is not much attention to prevent dust emission during different construction work

Dry ash collection in open truck from the silos needs to be curbed

Chapter 4 -

Ash pond area needs action plan to reduce dust emission


4.5 Solid Waste

Main solid waste from coal-fired thermal power plant is ash from combustion of coal. Coal contains 25-40% ash and the generation of ash depends upon that. At BTPS, average ash content of coal remains close to 30%

Ash is produced in two forms. About 20% of the ash in coarser form remains at the bottom of the boiler, called bottom ash. Rest of the ash as fine particulates flow out with the burnt gases. These particulates are collected in econornisers, superheaters and mostly in ESP at the end. This is called fly ash. At present both bottom ash and fly ash for Unit 5 are being disposed to ash pond as ash slurry

There are two ash ponds side by side located at Palpara at a distance of about 1 km from the plant. When one ash pond is used, the deposited ash from the other one is excavated. Each ash pond is about 750 m long and 150 m wide. These ash ponds are alternatively used. These ash ponds after getting filled up are mechanically excavated and the ash loaded in trucks to be finally used for filling of low lying areas, highway construction etc. Fly ash from other units 1-4 are being stored in two silos each of 1600 m3 capacity. The collected fly ash is being used by different private agencies for brick making and other uses. Figure 4.2 shows the solid waste generation and use.

Total ash generation and their use are given in Table 4.3 and Table 4.4.

Table 4.3

Average Power Generation, Coal Consumption And Ash Generation 2006 - 2007

Month

Apr'06

May'06

Jun'06

Ju1'06

Aug'06


Generation <MU>

248.743

168.729

108.820

124.020

103.730

67

Coal Consumption

<MT> 149246

118110

76 174

86814

7261 1

Ash (%)

30

30

30

30

30

Bottom Ash In <MT> 8954

6074

4178

5 209

4356

Fly Ash In <MT>

35819

24297

16715

20835

17427

Total Ash In<MT>

44773

30371

20893

26044

21 783

Ash Generation per Day = 843.01 MT Bottom Ash per Day = 168.79 MT Fly Ash per Day - - 907.00 MT

-

Table 4.4


Issues

After renovation it is expected that fly ash from Unit 5 will be collected dry. So more use in brick field and other uses need to be found.

Chapter 4

Ash Utilisation For The Period Of April 2006 To March 2007

4.6 Hazardous Waste

Month

Coal-fired thermal power plant does not produce any hazardous waste from power generation. However there are some other wastes from auxiliary activities that

Fly Ash(MT)


Pond Ash(MT)

68

Total Brick I Land 1 Total I Brick I Land I Total Quantityof

generate some waste categorised as hazardous waste by Hazardous Wastes (Management and Handling) Amendment Rules, 2002. Also different used containers of acidic, alkaline or toxic substances are also to be regarded as hazardous wastes.


At present the used oils and used lead batteries are sold to the certified users only. There is no proper accounting of used containers from laboratory. However the used oil drums are not stored properly and can be see dumped randomly at different places.

Chapter 4

The used batteries are also dumped outside.

Issues

Proper storage place for batteries and used oil drums

Proper accounting of all the hazardous wastes

4.7 House keeping

There is in general a significant lack in house keeping. There are uncared bushes in different parts of the plant and often scraps, debris, used oil drums etc. are dumped in those areas. A large area of the plant has been turned into unplanned scrap yard. The area is not at all maintained.

There is also lack of cleaning the plant premises. Unauthorised cattle are found in the main plant area. This overall lack of housekeeping has kept the coal stockyard area quite full of dust, the oil pond surrounded by bushes without any maintenance of the oil pond. The same scenario is also seen in other office zones outside the main plant area where the compounds are uncared and is full of bushes and weeds.

Issues

Requirement of a proper scrap yard

Better housekeeping

Sm SGS India Private Limited

Figure4.l Present Wastewater Management

Boiler Blow Down i

I I

Ash Water sump

I I

Bottom Ash Trench

CW Outlet

I Misc Service Water I

I

C o n l i n ~ Water O~ltfall Channel

1 Storm Water W Septic Tank

Auxiliary Cooling Water L

t t r

I Laboratory I I I Canteen Water I

74 m3ld D M Plant

Township Sewage

A A D

Irrigation

Oil handling Area

Coal Yard Area

Ash Pond v A F

b

b

4052 m3ld

Oil Pond

Plant Sumps ce

Stone, Bould er, Iron Sorter Out & Reiect

Flying

Dust Sludg li Pulverised Coal Used for Steam Generation 8 Reject Stacked within Plant Boundary for Possible use as

[( Ash Periodic

removed

No.l,ll,lll,lV into Units in

To Construction

Discharged collected Ash from ESP of Unit No.l,ll,lll,lV into

. Various Scrap Cables, Wires, Tube Light, Insulator's, Fan Blades Etc.

Discharged collected Ash from ESP of Unit No.V in

- Various Ferrous & Non Ferrous Scrap

I I

Sweeping

Reconditioni Garbaae

Periodic Excavation removal of ash from Pond & Utilized in Different Purpose

Brick Field

For Low Land Filling

Road Construction

5.1 Introduction

5.2 Coal Consumption

5.3 Auxiliary Power Consumption

5.4 Unit Heat Rate

5.5 Auxiliary Fuel Consumption

5.6 Water Consumption


5.1 Introduction

Resource efficiency assessment is an indirect way of environmental audit, as less resource consumption will have less impact on the environment. It is generally more a part of energy audit where resource consumption is linked with energy use. For coal fired thermal power plant resource efficiency is mostly concerned about two major natural resources required for the plant operation - Fuel and Water. In coal fired thermal power plant, mail fuel is coal. Use of water mostly depends on the type of cooling system adopted in the plant. The following discussion focuses on these issues, mainly regarding Unit 5 which is for R&M programme .

5.2 Coal Consumption

Coal consumption data for the Unit 5 has been collected from the plant database. Monthly coal consumption and power generation for Unit 5 is given below in Table 5.1

Table 5.1 Monthly coal consumption and power generation for Unit 5

Considering all the months of operation average coal consumption is 595.01 16 MTI MU. If the month of December 05 is not considered because of being as a start up month, the average coal consumption is 594.704 MTI MU, a little lower. This low


consumption rate is due to high calorific value of the coal, 4945 KcaYKg and low ash content of 28.8%.

-

Since the emergence of the Kyoto Protocol and its Clean Development Mechanism (CDM), one of the important factors for resource efficiency can be described as C 0 2 emission factor. Based on the above data and following the guideline of Central Electricity Authority (CEA), (refer C02 Baseline Database for the Indian Power Sector User Guide Version 3.0 December 2007, Government of India, Ministry of Power, Central Electricity Authority) Specific C02 emission factor was calculated as given below:

Absolute C02 emission = yearly coal consumption x GCV X EF X OF GCV = Gross Calorific Value of the fuel for the year EF = CO2 emission factor based on GCV of the fuel OF = Oxidation factor of the fuel (User Guide pp 1 1) EF = 92.5 g C 0 2 N J and OF = 0.98 for coal (User Guide, Appendix B) Specific C02 emission = (Absolute C02 emission 1 Net Power generation) = 0.64 t/Mwh for the year 2005-06 for BTPS (Unit 5 was not under operation for most of 2006-07)


CEA has published C02 emission for the different grids of India for different conditions. To compare with the new power plants Built Margin (BM) condition is considered. Built Margin (BM) is the average emission of the 20% (by net generation) most recent capacity addition in the grid. Table 5.2 shows the weighted average specific emissions for fossil fuel-fired stations in FY 2006-07. Comparing with the data of 2006-07 the Specific CO2 emission of BTPS is quite low compared to the other fossil fuel fired stations.

Chapter 5

Table 5.2

Weighted Average S~ecific Emissions For Fossil Fuel-Fired Stations -. . - - - - - . , - - s

Zone 1 Coal I Disl I Gas 1 Lign I Napt I Oil Nnrth 1 1.09 1 1 0.44 1

Government of India, Ministry of Power, Central Electricity Authority.

East South West North-East India

f SGS India Private Limited

Source: C02 Baseline Database for the Indian Power Sector User Guide Version 3.0 Dec

1.13 1.01 1.10

1.09

0.62

0.64 0.62

0.49 0.45 0.69 0.47

1.43 1.36

1.42

0.66 0.61

0.61

0.61 0.82

0.77


5.3 Auxiliary Power Consumption

Auxiliary power consumption is another indicator of performance of a power station. Lower the consumption, better the performance. Table 5.3 shows the auxiliary power consumption in Unit 5.

Table 5.3 Auxiliary Power Consumption in Unit 5

Considering all the months of operation, average auxiliary consumption is 9.94%. This is higher than the average consumption rate of 9% considered for 210 MW as given by CEA, refer Table 5.4

Table 5.4 Auxiliary Power Consumption Assumption at Unit Level

(by capacity; only for units in the BM, where data was not provided by station)

Consumption Specific 1 .05 1 .OO Emissions

Source: C 0 2 Baseline Database for the Indian Power Sector User Guide Version 3.0 December 2007, Government of India, Ministry of Power, Central Electricity Authority.

5.4 Unit Heat Rate

Unit Heat Rate is another factor to compare the resource efficiency of the plant. The coal consumption, power generation and calorific value of coal determine the unit heat rate. The monthly coal consumption and monthly average CV of coal for Unit 5 is given in Table 5.5

SGS SGS India private Limited 72

Table 5.5 Coal Consumption and Average CV of Coal for Unit 5

-

Considering all the months of operation (except Shut down month) Unit heat rate is 2942.77 KcaVKwh.

CEA carried out a study of efficiency (station heat rate) of thermal power stations for environmental aspects in power sector during the year 2006-07. The analysis of Heat Rate for 56 TPS aggregating to a capacity of 3861 1 MW was carried out. The analysis revealed that the operating station heat rate had been 2861 KcaV Kwh against the design heat rate of 2398 KcaVKWh having percentage deviation of 19.31 %.


Considering the above study, Unit heat rate for Unit 5 is not satisfactory, having a deviation of 22.7%. CEA's general assumption for new units, assume net heat rate of 2747 KcaV kwh (refer Table 5.6). which is also lower that the heat rate of Unit 5.

Chapter 5

Table 5.6 Net Heat Rate Assumption at Unit Level

(only for units in the BM, where data was not provided by station)

/ coal I Unit 1 67.5 1 120 1 200-250 1 500MW 1 I MW I MW I MW

Net Heat Rate I KcaV kwh 1 3125 1 2747 1 2747 1 2622 Source: C 0 2 Baseline Database for the Indian Power Sector User Guide Version 3.0 December 2007, Government of India, Ministry of Power, Central Electricity Authority.

SG$ SGS India Private Limited

5.5 Auxiliary Fuel Consumption

- -

Auxiliary fuel consumption is another indicator of performance of a power station. Lower the consumption, better the performance. Table 5.7 shows the auxiliary fuel consumption in Unit 5

Table 5.7


Chapter 5

Specific fuel consumption for Unit 5 from above is 1.46 mVKwh. Comparing with Table 5.8 which assumes average Specific fuel consumption as 2.0 mVKwh.

Auxiliary Fuel Consumption in Unit 5

Table 5.8 Specific Oil Consumption Assumption at Unit Level

(only for units in the BM, where data was not provided by station)

Aux Fuel Cons Month


Power Generation

Coal

Specific Oil Consumption

Water is another major natural resource required for thermal power station. Major requirement is for

Condenser cooling Auxiliary Cooling DM water

Source: C 0 2 Baseline Database for the Indian Power Sector User Guide Version 3.0 December 2007, Government of India, Ministry of Power, Central Electricity Authority.


Unit

ml 1 kwh

120 MW 2.0

67.5 MW 2.0

200-250 MW 2.0

500MW

2.0

Comprehensive Environmental Audit and Due Diligence 1 Chapter 5 1 Assessment of the Bandel Thermal Power Plant -

Service water Ash water

About 27000M3/hr. of Cooling water is required for condensing this exhausted steam. The cooling water is supplied by 3 nos. 33.113% capacity, vertical mixed flow pumps of 9500M3/hr. capacity each at 16.6 MWC head. These pumps are located in the intake pump house situated on the River bank by the side of the existing intake pump house.

4 Nos. Raw Cooling water pumps are provided for meeting the cooling water requirement of 5 nos. turbine Oil Coolers and 8 nos. D.M. C.W. heat exchangers. The pumps are vertical mixed flow type and have a capacity of 2400 M3/hr.each, at 33.53 MWC head. Two pumps are sufficient to meet the full load requirements and two remain stand by. They draw water from the river

Two (2) nos. pumps of 100 M3/hr. capacity each, at 72 M.W.C. pressure are provided which take suction from the well water tanks.

Two (2) nos. D.M. water service pumps of 60 ~ ~ / h r . capacity at 36 M.W.C. pressure have been provided for supplying make up to D.M. cooling water system

Ash water is drawn from cooling water return

Total water consumption for the BTPS is given below

Water Consumption Data For BTPS (2006-2007)

However as there is no metering at any point, all the water consumption data submitted to WBPCB and kept in record are theoretical. So no resource efficiency can

q%;s SGS India Private Limited

be assessed from the present condition. Also as there is no control system at the CW intake pumps, there cannot be much control of inflow of water related to power generation. Only one of the three pumps can be closed if the generation goes down much.

However as this is a once through cooling system the cooling water is returned to the river. In reality only a very small part of river water is wasted which is used for ash water for carrying the ash to the ash pond. In future with the adoption of dry fly ash extraction system for Unit 5, the requirement of ash slurry water will be reduced by about 80%. The more important issue therefore will be accounting of ground water withdrawal which is partially used up and rest goes out as wastewater.

Chapter 5 -

Resource Vs Generation


+Coal Cons ( 1 00 MT) 1 I -m- Power Generation (MU) 1

I I Aux Fuel Cons (KL) I

+Total water consumption (1 00000 KL) 1

I SGS SGS India Private Limited I 76 I

6.1 Health and Safety Aspects from Chemicals

6.2 Fire & Mechanical Safety

6.3 Accidents

6.4 Fire fighting Facilities

6.5 Issues

6.0 OCCUPATIONAL HEALTH & SAFETY

6.1 Occupational Health and Safety Aspects from Chemicals

Chapter 6 -

Plant operation will involve storage handling and use of fuels and several chemicals. Some of these chemicals may be hazardous in nature. Information about these chemicals is therefore important for the safety of the employees and the plant. Besides, the health status of the employees is also important which may be affected due to exposure to these chemicals. The exposures may be sudden and accidental or for a long period. In both the cases there will be different health effects. Therefore safety measures dealing with these chemicals are of vital importance.


Fuel Oil

Fuel oil will be used as alternative fuel for combustion in the boiler. The fuel oil stored in bulk is LDO. It is a flammable liquid with average flash point about 66°C. Main hazard in the storage areas and pipeline is serious fire due to any leakage of oil and its coming in contact with a source of ignition preventing measures. The storage tanks are constructed and maintained as per the guidelines laid down in the Petroleum Rules

Dust Hazard

Coal dust can be major health hazard if not proper environmental management is carried out. Coal stockyard, transfer points, coal handling and sizing plant, ash transfer can be sources of dust pollution.

Chemicals

Different chemicals like Chlorine, hydrochloric acid, sulphuric acid etc. will be required for water treatment, DM plant, effluent treatment, etc. Handling of hazardous chemicals involves risks to workers as they are constantly exposed to these chemicals during various operations and storages. In the event of an accident, not only the workers but also the general public can be exposed to dangers.

Hazardous Chemicals in Plant

* To be considered as Major accident hazards (MAH) installations.


BTPS management has deputed for past several years a trained doctor in a local medical clinic that caters to basic need of the workers, their family and local residents of the area. However, the existing medical facility is very basic and is not staffed or equipped to undertake a regular and complete health check-up of the employees.

-

The practice of a regular health check up is not followed at BTPS and there are no records available to indicate occupational history of health impact on workers and residents of the area. 150 of the total 925 employees, with incomes less that Rs 7500 per month are covered under GSI, and all contract employees are also reportedly included under the same insurance scheme. There is no such Health policy of BTPS.

6.2 Fire & Mechanical Safety


Major Hazards from oil storage can be fire. Maximum credible accidents from oil storage tank can be a)Tank Fire and b) Pool 1 Dyke fire. There can be fire in the main plant area, electricity distribution areas, the cable galleries, and coal handling areas, mainly coal conveyors, transfer points, and tunnels.

Chapter 6

For safety of working personnel the areas of special concern are - all easily accessible moving parts in the plant, every hoist, crane etc, the boilers and other heavy machineries.

Trainings are organized by plant authorities. Training on "Safety In Operation And Maintenance Of Power Plant" Organised by M s . Loss Prevention Association of India, Kolkata is provided time to time. Following is the list of people trained.

Table 6.1

Safety Training List

28.07.03 - 29.07.03 30.07.03 - 3 1.07.03 15.09.03 - 16.09.03 17.12.03 - 18.12.03 19.12.03 - 20.12.03 25.02.04 - 26.02.04 27.02.04 - 28.02.04 15.03.04 - 16.03.04 17.05.04 - 18.05.04 19.05.04 - 20.05.04 07.07.04 - 08.09.04 09.09.04 - 10.09.04 17.03.05 - 18.03.05

Total ...

38 heads 42 heads 42 heads 36 heads 42 heads 33 heads 33 heads 39 heads 21 heads 21 heads 38 heads 40 heads 37 heads 462 heads

ses SGS India Private Limited 78


3 (three) days training of National Safety Council at different states (i.e. Mumbai, Bangalore, Chandigarh, Coachin, Jaipur, Bhupal, Kokata) in 1ndia.i~ also organised and have been attended 44 people.

Following Safety Equipments are reported to be available to the Technical Employees

1. Safety shoe.

2. Safety Helmet

3. Ear plug

4. Dust Mask

However very few wear dust masks. The condition of the dust masks worn by a few construction workers during plant visits were quite unsatisfactory

6.3 Accidents

Accidents occurred in the plant are documented by the Safety Department. However the documentation provided was not satisfactory as the record only shows the name of the person, date of occurrence and type of accident very briefly. The details of injury and the cause, loss of man-days etc. are not available. The remedy for such accident is not also considered. Detailed information needs to be recorded and stored for quick dissemination. Accident document for last 3 years are given in Table 6.2. The summary of the accident is given below

No major fire has been reported in last 5 years.

Table 7.2 List of Accidents 20042006

Year 2006 2005 2004

Year 2004

No of Accidents 6 9 13

Bum Case 0 0 2

Remarks Mostly mechanical injury handling different machineries

S1. No.

1 2 3

4 5


NAME

Swapan Kr. Biswas Pratap Singha Parasuram Tiwary

Sujay Kr. Chakraborty Ramen Barman

79

Date of Accident 06.01.04 29.01.04 03.02.04

10.02.04 13.04.04

Cause of Accident

Right hand injury Traumatic injury base of left thumb Sprained ankle with sprained tibotelar ligament Burn injury Prolapsed intraratiobul disc

Year 2005

-

Year 2006

6.4 Fire fighting Facilities


For protection of the plant against fire, all yards and plant are protected by any one or a combination of the following systems: -

Chapter 6

SGs SGS India Private Limited

a. Hydrant system

b. Automatic high velocity and medium velocity sprinkler system

c. HV & MV water spray (Emulsifier system)

d. Portable and mobile chemical extinguishers

A list of all the equipment and the facilities are provided in Annexure 3.

6.5 Issues

Chapter 6

m

This study does not attempt to review the details of fire fighting facilities or other safety facilities. The study attempts to find out the absence of the system which will ensure the safety to the workers and the plant.


Except fire fighting facilities, there is hardly any safety system operating. However other equipment like safety goggles, gloves for different purpose, asbestos safety boots etc are not mentioned.

There is no proper documentation about the health of the workers and there is inadequate information about the occupational health aspects of the workers

There is no documented procedure to have periodic health check up of workers.

There is no arrangement of rotation of workers from hazardous working area to minimise exposure

A proper safety equipment list needs to be prepared and the materials need to be obtained urgently.

There is no On-site Emergency Plan to meet the emergency situation

There is no provision of safety drills of the workers.


7.1 Introduction

7.2 Community Reaction

7.3 Issues


7.1 Introduction

Potential liabilities include the impact on local communities for the operation of the plant. This would mean the socio-economic impact on the people who lost land for the project, livelihood aspects of the project affected people (PAP) and the environmental impact on the local community and ecology.

As this plant was established more than four decades ago, no immediate information on land related questions was available. The present economic status of the people who sold their land could have been a good indicator for the impact of development in this area. It is envisaged that social impact audit is going on and that would carry out this task.

7.2 Community Reaction

BTPS was established in 1966 when the population density was low in the vicinity. As the locality became densely populated the complaints about dust pollution from BTPS started to pour. This led to a form of mass agitation in 1989 when a number of mass meetings demonstrations etc. took place. The issue was widely reported in print media too. A committee named 'Chhai pirit Nagarik Committee' (Ash affected Citizens Committee). However all these allegations were mostly against emission from Unit 1 to 4 and fugitive emission from the trucks carrying ash from ash pond. By the end of 1996 ESPs were installed into all the four old units and the public outcry mostly subsided.

However there are still some complaints from local residents. Dr. Subrata Laskar, Professor of Chemistry in Burdwan University has been a part of this movement for quite a long time. We had a long interview with him about this issue. On 26 September 2007, we also met the members of 'Players Club', local community organisation to hear about their views on the issue. This locality called Refaitpur is less than a kilometre away towards North and falls in the downwind zone of the plant for most of the time of the year. We also visited a number of houses and orchards in the locality. A questionnaire was circulated among the local people to obtain their views.

Though overall air pollution has decreased, the local people complained about intermittent pollution episodes. Probably this occurs after shutdown period, when the unit is started on supporting fuel. People has complained about the dust pollution affecting their day to day life, making their clothes and household goods dirty. Most


of the interviewed people complained about a number of eye and breathing related diseases due to air pollution from the plant. They demanded better air pollution control.


Another complaint was the long-term impact on local ecology. A local resident took us to his orchard and said that the productions of different fruits have been affected. He showed us small coconuts which are the examples of air pollution.

Chapter 7 1

A major complaint was about noise. During start-ups the noise sometimes is so high that even people at their home at one kilometre away gets disturbed. The students cannot study at that time.

A few sample complaints are given in Annexure 4.

There have been 25 times shutdown in seven months from January to July 2007. A List of the Shutdowns is provided in Table 7.1.

Locals also have grievances that BTPS authorities are not sensitive to their complaints. They complained that there is no measurement of pollution levels, no measurement of noise pollution from the plant and no arrangement for health check up too. The authorities are not sympathetic to their complaints.

Table 7.1 Shutdown Details Jan -July 2007

Dated Concerned Unit Shutdown Duration 24/07/07 Unit # 4 13:25 Hrs. - 22.07.07 04: 15 Hrs. (14:00 Hrs. to 18: 15 Hrs. -

24/07/07

21/07/07

21/07/07

07/07/07

23/06/07

12/06/07

07/06/07

06/06/07

22/05/07

12/05/07

07/05/07

Unit # 1

Unit # 4

Unit # 1

Unit # 1

Unit # 3

Unit # 4

Unit # 4

Unit # 1

Unit # 4

Unit # 2

Unit # 4

SF;\$ SGS India Private Limited

13:35 Hrs. - 22.07.07

12: 1 1 Hrs. - 18.07.07

23:40 Hrs. - 11.07.07

19:07 Hrs. - 05.07.07

00: 15 Hrs. - 17.06.07

83

04:25 Hrs. (14:00 Hrs. to 18:25 Hrs. - 22/07/07) 02:30 Hrs. (16:40 Hrs. to 19:lO Hrs. - 18/07/07) 09:25 Hrs. (20:00 Hrs. 12/07/07 to 05:25 Hrs. - 13/07/07) 05:lO Hrs. (1 1:00 Hrs. to 16:lO Hrs. - 06/07/07) 08:35 Hrs. (02:05 Hrs. to 10.40 Hrs. - 2 1 /06/07)

0950 Hrs. - 11.06.07 04.00 Hrs. (1 1:30 Hrs. to 15:30 Hrs. - 1 1/06/07)

19:32 Hrs. - 03.06.07 07:45 Hrs. (02:22 Hrs. to 09:45 Hrs. - 07/06/07)

01 : 16 Hrs. - 02.06.07 1050 Hrs. (16:05 Hrs. on 05/06/07 to 02:55 Hrs. - 06/06/07)

09:39 Hrs. - 22.05.07 02:lO Hrs. (10:05 Hrs. to 12:15 Hrs. - 22/05/07)

10: 15 Hrs. - 09.05.07 0655 Hrs. (02.30 Hrs. to 09:25 Hrs. - 1 1 /05/07)

05:30 Hrs. - 01.05.07 05:15 Hrs. (13:00 Hrs. to 18:15 Hrs. - 0 1 /05/07)


Chapter 7

7.3 Issues

Due to high level of emission from BTPS before 1996, local community has a negative image about BTPS. Though at present the emission gets worse only intermittently, the image of the company still has to recover. As discussed before that old four units had to be shut down often for different technical reasons, their start up eventually cause pollution. It seems that till these old units are phased out in coming years, the problem will come up time to time.

06:OO Hrs. (14:55 Hrs. to 20:55 Hrs. - 30/04/07) 04:35 Hrs. (17:05 Hrs. to 21:40 Hrs. - 06/04/07)

Besides, BTPS is yet to start any meaningful social service to the community. A regular interaction, information dissemination on pollution episodes, periodic monitoring, medical check ups etc can help to subside the negative impression and develop positive relation with the community.

00:27 Hrs. - 28.04.07

00:42 Hrs. - 06.04.07

02/05/07

09/04/07

BTPS is operating here for four decades. There is an urgent need that a detailed ecological study should be camed out to find out the environmental impact of the power plant for its operation for last 40 years.

Unit # 3

Unit # 1

3 1 /03/07

14/03/07

08/03/07

05/03/07

2UOU07

20/02/07

17/02/07

14/02/07

17/01/07

0810 1/07

08/01/07


-- Unit # 3

Unit # 4

Unit # 2

Unit # 3

-- Unit # 4

Unit # 1

Unit # 1

--- Unit # 2

Unit#4

Unit # 1

Unit # 3

00:25 Hrs. - 27.03.07

04:45 Hrs. - 08.03.07

-

08:lO Hrs. (15:25 Hrs. to 23:35 Hrs. - 27/03/07) 08:05 Hrs. (01:00 Hrs. to 09:05 Hrs. - 14/03/07)

02:58 Hrs. - 03.03.07 02:35 HKS. - 08/03/07)

20:03 Hrs. - 02.03.07 04:25 Hrs. (10:20 Hrs. to 14:45 Hrs. - 03/03/07) --

21 :07 Hrs. - 15.02.07 07:15 Hrs. (03:15 Hrs. to 10:30 Hrs. - 17/02/07)

16:37 Hrs. - 17.02.07 07:25 Hrs. (01:35 Hrs. to 09:OO Hrs. - 20/02/07)

20:39 Hrs. - 14.02.07 06:25 Hrs. (04:50 Hrs. to 11 : 15 Hrs. - 14/02/07)

23140 Hrs. - 10.02.07 02:10 Hrs. (02:00 Hrs. to 11: 10 Hrs. -

02:47 Hrs. - 02.12.06

07:05 Hrs. - 02.01.07

04:42 Hrs. - 04.01.07

04/02/07) 05:35 Hrs. (05:05 Hrs. to 10:40 Hrs. - 1 610 1/07) 08: 15 Hrs. (21 :00 Hrs. on 03/01/07 to 05: 15 Hrs. - 04/01/07) 05:OO Hrs. (07:30 Hrs. to 22:30 Hrs. - 0410 1/07)

8.1 Introduction

8.2 Present Environmental Responsibilities and

Management

8.3 Environmental Management System

8.4 Emergency Response Plan

8.5 Occupational Health Monitoring system

8.6 Laboratory

1 Comprehensive Environmental Audit and Due Diligence Assessment of the Bandel Thermal Power Plant

I chapter ~

8.1 Introduction

Institutional Capacity Assessment (ICA) for this study specifically assesses the environment related capacity issues only. ICA is a process to review the existing resource of the organisation dealing with different environmental requirements. It then identifies the inadequacies in the present scenario and suggests the changes and additions to the present system. For achieving any environmental compliance and target, the organisation needs proper resources - physical, technical and human resources - to build its management capacity. It is with this view the following exercise is canied out.

8.2 Present Environmental Responsibilities and Management

Main environmental responsibility of the plant is to achieve the environmental compliance as stipulated by WBPCB (refer Chapter 3.0). The routine task mainly consists of

Arranging and supervising of monthly monitoring of different parameters

Arranging monitoring facilities for WBPCB

Filing different statutory forms to WBPCB including environmental statements

Obtaining yearly consent to operate the plant from WBPCB

For achieving this compliance the responsible person has mostly to see that the effluent qualities are within the permissible norms. As there is no quantitative measurement of water consumption or ash generation, these data are provided on theoretical basis.

For last two years, WBPCB has asked for more comprehensive effluent treatment and wastewater reuse and the BTPS authority carried out some studies on that. A


Comprehensive Environmental Audit and Due Diligence Assessment of the Bandel Thermal Power Plant I Chapter8 I

consultant was appointed who prepared a DPR for 'Effluent Treatment and DisposalIRecycle System'. In the meantime, BTPS has been able to collect all fly ash from Units 1-4 in dry way and Unit 5 is also ready for such change but being delayed for some equipment constraints.

Environmental issues in the plant are nearly solely managed by Mr. Anjan Roy, Manager, Environment. Fire safety is supervised by Mr. Tapan Pathak, Assistant Manager, Safety is supervised by Mr. Pranab K Ghosh, Junior Manager. Mr. S.S. Kar, Senior Manager, Civil and Mr. B.N.Baura, Senior Manager C & FE Division were also involved in this study However Mr. Anjan Roy is only responsible official for environmental compliance and dissemination of environmental information. These concerned officers report to Plant Head to disseminate the information to WBPDCL head quarter.

Issues

Major inadequacies in the present scenario is that

There is no documented Environmental Management System in the Plant

There is no On-Site Emergency Plan of the Plant

No Occupational Health Monitoring system in the plant

There is practically no use of computer in data collection, storage or

dissemination.

A brief description of all the above requirements specific to the plant is given below

8.3 Environmental Management System

An Environmental Management System (EMS) can be described as a program of continuous environmental improvement that follows a defined management sequence of steps drawn from established project management practice and routinely applied in business management. In simple terms these steps are

Review the environmental consequences of the operations.

Define a set of policies and objectives for environmental performance

Establish an action plan to achieve the objectives

Monitor performance against these objectives

Report the results appropriately.


Review the system and the outcomes and strive for continuous improvement

Not every system will present these steps in exactly the same way, but the basic principles are clear and easily understandable. The IS0 14000 series is a series of standards for different aspects of environmental management.

Chapter 8 -

Environmental Management Systems thus will include


Policies, procedures and protocols; Management information systems; Environmental assessment; Quality assurance; to check compliance with environmental requirements Risk assessment and risk management; conducts sampling programs to monitor air

and water quality Environmental regulatory affairs; Day-to-day compliance management; Environmental planning; Training and education; considering the special requirements for quality assurance Communication; and that accompanies regulatory monitoring and reporting. Environmental audit. Public complaint and grievance redressal

Environmental documentation should include

Major technical information on Thermal Power Plant Organisational Charts Environmental Monitoring Standards

$ ci S SGS India Private Limited 87

Environmental and related legislation Operational Procedure Monitoring Records Complaint Records Training Records Incident Reports Quality Assurance Plan for Monitoring Emergency plans

(IMCL

8.4 On-Site Emergency Plan

During the past decade there has been an increased public awareness of disaster situations which lead to emergency. A number of laws have The plant under discussion handles a number of hazardous chemicals and some operations which can lead to emergency situation. Therefore it is necessary statutory requirements to draw up an On-site Emergency Plan for the plant to meet the emergency situation.


The obligation of an occupier of hazardous chemicals to prepare an On-site Emergency Plan is stipulated in Rule 13 of the Manufacture, Storage and Impact of Hazardous Chemicals Rules, 1989 under Environment (Protection) Act, 1986. Section 41B (4) of the Factories Act, 1948 (as amended) also states to draw up an On-site Emergency Plan with detailed disaster control measures.

Chapter 8

"The Manufacture, Storage and Import of Hazardous Chemicals Rules, 1989 (as amended till now)" has defined a number of chemicals

Some of the important rules of "The Manufacture, Storage and Import of Hazardous Chemicals Rules, 1989 (as amended till now)" are given below.

Rule 4 states about General Responsibility of the Occupier which includes that the occupier has identified the major accident hazards and taken steps to prevent such major accidents and provided safety measures to the persons working there.

Rule 5 states about Notification of Major accident

Rule 7 states about Notification of Sites in which occupier has to inform the authorities within a scheduled period before undertaking any industrial activity involving hazardous chemicals.

Rule 8 states about Updating of the Site following changes in chemical quantity.

Rule 10 states about Safety Reports to be prepared by the occupier before undertaking the industrial activity.

SG ti SGS India Private Limited I


-

Rule 13 states about Preparation of On-site Emergency Plan before undertaking the industrial activity.

Rule 15 states about Information to be given to persons liable to be affected by a major accident outside the site.

Section 41B (4) of the Factories Act, 1948 (as amended) also states that every occupier is to draw up an on site emergency plan with detailed disaster control measures. The general public living in the vicinity is also to be informed and educated about safety measures and actions to be taken in the event of an accident.

Issues

On-site Emergency Plan should include

Objectives of On-site Emergency Plan Hazard Identification Disaster Scenarios Key Persons And Responsibilities Infrastructure for implementation Material Safety Data Sheets

8.5 Occupational Health Monitoring system

As discussed in Chapter 6.0 that there is virtually no proper documented system for Occupational health. For safety some data are kept but it is far from the requirement.

Therefore an Occupational Health Centre (OHC) is much required. Occupational Health Centre (OHC) should be staffed by professionally qualified and trained doctors, hygienist and paramedical staff equipped with clinical, pathological and other modem diagnostic equipment and work environment monitoring equipment

To ensure proper occupational health of employees and detect any problems well in time, the following medical check ups are to be conducted:

Pre-employment check up of employees: Before joining, an employee is to be thoroughly examined to ensure that he is medically fit to perform his duties. Annual medical check up of employees: All employees above the age of 40 have to undergo medical check up annually once. Check up of workers employed in hazardous area like coal handling areas, crusher house etc.

Work Environment Monitoring



i Chapter I Portable monitors for monitoring work area and individuals exposure to hazardous chemicals like particulates, ammonia etc.

Noise levels at different locations in the plant.

8.6 Laboratory

The plant at present has a laboratory headed by Mr. D.C.Bora1, Manager, Chemical.

The laboratory primarily canies out tests for proximate and ultimate analysis for the coal, combustible content in ash and water quality test for DM plant and raw water. Heavy metals are not tested in this laboratory. Any air quality test is also not done.

Major instruments are Colorimeter (Klett-Summerson), Spectrophotometer (Bausch & Lomb), Conductivity meter (Chemito), pH Meter (Eltech), Chenical Balance, calorimeter etc.

Various parameters being tested through chemical laboratory are stated as below: a) Air quality monitoring by

i) Orsat apparatus (By Orsat apparatus % of 0 2 & CO2 are measured)

b) Water quality monitored by

ii) Spectrophotometer ( For Fe, Cu, Si02, PO4 measurement) iii) Colorimeter (Si02, PO4 measurement) iv) Incubator / BOD analysis (E mark) v) COD analyzer (E mark) vi) pH meter (water quality) vii) Conductivity meter (dissolved solids measured)

Other than Air & water, laboratory performs some other tests also is as follows.

Various parameters of coal a) Ash %, b) Volatile matter % c) Fixed carbon % d) Equilibrated moisture content e) Calorific value of f) Sulfur - content of particular a Particular coal sample. Coal sample etc.

For Determination of the above, parameter the following equipment are used.

SGS SGS India Private Limited P

90


Chapter I

I I I the coal sample. I

Measure the % of ash in coal i)

ii) iii) Iv)

Ash furnace

OIL (Furnace & Turbine)

Volatile matter furnace Air Oven Desiccators

V)

a) Viscosity d) Specific gravity

Measure the % of ash in coal Measures the % of fixed carbon of coal Measures the % of equilibrated moisture content of

b) Calorific value C) sulphur d) specific gravity e) Moisture

Bomb calorimeter Measures the calorific value of the coal sample. By this calorimeter ; S content also measures by some others successive chemical reaction with other reagents. Starting from Bomb wash. (after burning of sample in Bomb calorimeter the residual)

The laboratory does not have any good documentation system and no computer is used for stock keeping or other laboratory information.

The disposal of used containers, bottles etc are not documented. There is no external audit done and there is no specific quality assurance plan.

Measure the viscosity of oil sample Measure the calorific value of oil Measures the % of moisture content in oil in %. Measures the % of moisture in ppm. level. Measures the weight of various chemical and used for measuring the sp. gravity of oil.

i) ii) iii) Iv) V)

As this study is more specific to environmental issues, it proposes to set up an environmental laboratory separately. In the new scenario as there will be a number of environmental mitigation systems, a more detailed and regular monitoring will be required. A new laboratory with specific objective and management system will be more useful to ensure environmental compliance and enhancement of environmental quality. This has been detailed in Chapter 9.

Kinetic Viscosity meter Bomb Calorimeter DEN & START meter Culfisture Metal balance lno. Balance 2 Nos.

I s&S SGS India Private Limited

9.1 Introduction


9.3 Wastewater Treatment and Disposal System

9.4 Cooling Tower Option

9.5 Ash Pond Water

9.6 Plant and Township Sewage

9.7 Air Pollution Control

9.8 Noise Control

9.9 Laboratory

9.10 Social Intervention

9.11 Capacity


9.1 Introduction:

In the chapters before (Chapters 4 to 8), a number of deficiencies have been identified which restrict BTPS to achieve its targeted compliance for environmental consent and also to improve its environmental performance. It may be mentioned that the first unit of the plant has been commissioned in 1965 and the fifth unit was commissioned in 1983. As during that period there was not much control on environmental issues, the plant did not have a proper environmental management system. Though the plant is mostly attaining all the limits for effluent disposal qualitatively, there is no arrangement for quantitative compliance. The following sections discuss the interventions needed for environmental compliance and improve the environmental quality of the plant operation.

At present it is being envisaged that the Units 1 to 4 will be decommissioned within few years and the renovation and maintenance programme will be taken up for Unit 5 only. The following interventions are specifically mentioned for Unit 5 though the interventions for Unit 1 to 4 can be taken up in similar manner


Water required for the plant operation is made available from the river Hugli and partly from the ground water. There are no measurement facilities at any of the pumps inlet or outlet. Therefore it is simple that there should be arrangement for measurement of water withdrawal at all the pumps withdrawing water from the river or underground for Unit 5. This is required for proper compliance of the WBPCB's requirement of water consumption and also to review the resource efficiency for water use.

Therefore metering facilities are required for (Unit 5)

Metering Facilities

Pump meters, connections to the control room and data acquisition system.

a) Three (3) cooling water vertical mixed flow pumps of 9500 ~ ~ / h r each

b) 4 Nos. Raw Cooling water pumps of 2400 M3/hr.each

c) Two (2) nos. pumps of 100 M3/hr. capacity for service water

SlfS SGS India Private Limited 92

I Comprehensive Environmental Audit and Due Diligence Assessment of Chapter 9 the Bandel Thermal Power Plant -

d) Two (2) nos. D.M. water service pumps of 60 ~ ~ / h r .

All the metering system should be directly linked to the plant control room so that flow can be monitored from there and also cumulative flow can be recorded. The water withdrawal should be connected to DCS system.

9.3 Wastewater Treatment and Disposal System

As discussed in Chapter 4.0 that besides the neutralisation pit in DM Plant, there is no wastewater treatment system existing in the plant or in the colony. Moreover there it has been also discussed there that the wastewater streams have been mixed with each other at random. Thus the number of disposal points has also crossed the limit set by WBPCB.

Thus following interventions are proposed for Wastewater Treatment and Disposal System. The changes specifically for Unit 5 have been considered.

Basis of Wastewater Treatment and Disposal System is Zero-discharge as stipulated by WBPCB.

A. Coal Stockvard

Contaminated storm water from coal stockyard is expected during rainy season only or during occasional rains in non-monsoon period. The water will be led to the existing oil pond (Tel Pukur) which will provide settling time for the particulates. The existing pond will have to be cleaned, excavated and should be suitably lined by clay bamer. The inlet water can be distributed through a number of channels at the entry of the pond. Considering the space constraint there should be a provision of overflow weir at the inlet to divert the excess storm water flow after initial minutes of heavy rainfall. The water from this pond can be used for dust suppression in the Coal stockyard area. During monsoon overflow from this pond can be disposed to the outside channel. As this is basically contaminated storm water, excess storm water should be discharged to storm water channel and this will not violate zero-discharge concept

Design parameters for the systems are

Coal yard area and related area = 45,000 m2 [Coal yard = 265 m x 150mI


The existing drains have to redirected to opposite direction to take advantage of Oil- pond to be used as settling basin. There are 3 surface drains 265 m long, 1 m wide and 1 m depth.

Considering 50 mm /hr rain for 15 min, and 70% runoff, total volume of water will be about 400 m3. Considering 100 mm rainfall for 24 hours, volume of runoff will be 3150 m3. 'Tel Pukur' holding tank is a triangular one with surface area about 1250 m2. Excavating it to 3 m, it can hold 3750m3 water. The inlet water can be distributed through a number of channels at the entry of the pond. Final water to be disposed. Arrangement to be provided to by pass during heavy rain. Water from the pond can be used for dust suppression, gardening etc. The pond to be cleaned off in summer.

-

B. Oil Loading/ Unloading Area

The existing oil unloading facility has the capacity to unload a rake of 70 oil tanks in a day. Generally the requirement is once in 2 months which cater for requirement for total power plant. The cleaning after loading unloading generates the oily effluent. Considering the drain width of 500 mm, effluent depth of 50 mm and flow rate of 0.3 mlsec, a design flow rate of 27 m3/hr has been considered. This will take place once in 2 month. Besides there will be storm water from the unloading area containing oil. The flow will be passed through an API Separator. The overflow from the separator will be sent to the Guard Pond for equalisation before reuse/disposal. There should be a provision of overflow weir at the inlet to divert the excess storm water flow after initial minutes of heavy rainfall.


There will be arrangement for collection of the separated oil. Separated oil has to be further gravity separated from the water coming with it. This oil can be sold as used oil as done for hazardous waste or can be burnt in boiler as supplementary fuel.

Chapter 9

Area requirement will be about 30 m x 15 m. This can be located in the proposed oil collection sump below the oil drainage trench as shown in Plot Plan - Drg 2004008/PE/SK-0 1.

C. Other Phnt Drains

Other plant drains from Unit 5 and other units would include

Boiler blow down


Comprehensive Environmental Audit and Due Diligence Assessment of Chapter 9 the Bandel Thermal Power Plant

Inmu.

DM Plant Effluent

Canteen Wastewater

Toilet wastewater

Laboratory wastewater

Cleaning and washing water

Of the above streams, existing treatment system of toilet wastes through septic tanks and soak pits will be continued.

Canteen wastewater Treatment - This stream contains mostly oil and other organic materials will be treated in a treatment plant specific for it. The wastewater will be passed through a screen to separate the larger particles and food wastes. The wastewater will then be first settled to remove floating oils in a settling tank and then mixed with lime and alum and then to settle particulates further. The clear water from the top will be sent to the ash water sump.

Canteen flow will be intermittent and total flow in a day will be about 15 -20 m3. After screening this water will be hold in a settling tank of 20 m3 in volume and then treated in a small package type alum-lime dosing and settling system. The space required for this treatment scheme is available by the side of the canteen.

Wastewater Treatment for other streams - All other streams will mainly contain suspended solids; traces of oil and some dissolved chemicals. All the streams will be collected in a equalisation tank and then passed through a Parallel Plate Interceptor and then led to Guard pond.


Boiler Blow down (for Unit 5 and three (3) 60 MW units ) - 15 m3/hr Laboratory wash water - 1 m3/hr Surface drain - 2 m3/hr

This water can be collected in an equalisation tank with 8 hr holding time, (150 m3 capacity). The ovefflow is then passed through a Parallel Plate Interceptor and then led to Guard pond. Water from guard pond will be sent to the ash water sump to be used for ash handling.

Overflow from Bottom ash trench will be sent to ash water sump to be used for ash handling system.



Wastewater treatment system has been kept simple; as this treated water will either be used for dust suppression and ash handling mostly. So no elaborate treatment is proposed.

The treatment units wastewater streams can be accommodated in the location above the proposed scrap yard at the southern end of the plant at the location marked as 600'E - 800'E and 1400's-1600 S' as shown in Plot Plan - Drg 2004008PElSK-01.

It may be noted that because of dry fly ash collection in all the units, there will be no water requirement for fly ash handling for any ubits. Total treated water can be used for Bottom ash handling.

Figure 9.1 shows the Schematic diagram for the Proposed Wastewater Treatment and

Disposal System.

D. Renovation and redesianinn o f existing wastewater disposal system

It has been discussed that different wastewater streams from different sources were mixed at random for easiest disposal opportunity. This whole disposal needs to be renovated and redesigned to achieve proper environmental compliance recommended by WBPCB. The redesigning of the disposal system requires

Separation of storm water disposal system of the plant (except coal and oil handling area) and dispose storm water to the river separately through one (or two if required) outlet.

Once through cooling water should not be mixed with any other stream and disposed through the present outlet. If Cooling Tower is installed, this outfall would not be used.

Canteen wastewater should not be disposed with others but treated as mentioned before.

Neutralisation pit for DM Plant should be provided with online pH monitoring system

E. Guard Pond

It is always better to provide a guard pond which acts as an equalisation basin for all the treated effluents. Thus an extra load in any effluent streams can be diluted. The basin can be used as the sump for reuse of treated wastewater for gardening and dust

S G s SGS India Private Limited

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96

suppression. The excess water through an overflow weir will be sent to ash water sump. This will reduce the use of river water for ash handling. With these ideas a guard pond is proposed to be developed.

Comprehensive Environmental Audit and Due Diligence Assessment of the Bandel Thermal Power Plant -


Chapter 9

Total flow will be about 20 m3/hr from other drains and 8 m3/hr from DM plant neutralising pit. There will be intermittent flow from oil separator.

Tentative sizing of Guard pond- 48 hour residence - with design margin is 1500 m3. Considering depth of 1.5 m, the area required will be about 1000 m2.

It is also suggested to keep an outlet pipe line from the guard pond for disposal into

the river in case of emergency.

The tentative layout plan for the treatment plant with guard pond is given below.

9.4 Cooling System

There was some confusion about the continuation of once-through cooling system by using river water as the cooling water outlet will not be able to meet the new Indian specification of 5°C difference with intake water. Requirement of changing the once through cooling system to circulating type cooling tower system will be mostly decided by the compliance requirement. By Indian standards, the old plants are allowed to dispose wastewater with a temperature difference of 10°C and for new plants with a temperature difference of 5°C. However Indian standard also prohibits use of once through cooling for the power plants commissioned after 1 June, 1999 (EPA Notification [GSR 7, dated 22 December, 19881). World Bank standard allows disposing wastewater with a temperature difference of 3°C only. World Bank guidelines also consider a renovated plant as 'new' if it is renovated for a long term use of 10 or more years (PPAH, pp 427).

This idea mostly came from the existing cooling water outlet data. However it was shown before that at present the temperature is measured at the outfall of cooling water on the canal not at the outfall where it reaches the river. Our study (ref Sec 3.2 and Sec 3.9) has shown that the temperature difference remains within 3 "C, the required WB standard, at the point where it meets river. So there is no need to change the present cooling system. A meeting with WBPCB has cleared the issue and WBPCB has accepted the continuation of the system.

The confusion regarding attainment of required temperature difference prevailed as there is no arrangement to monitor water at the confluence of cooling water canal and the Hugli river.


Comprehensive Environmental Audit and Due Diligence Assessment of Chapter 9 the Bandel Thermal Power Plant -

CW outlet monitoring facility A proper pathway to the confluence for collecting water sample is required for monitoring the water quality

Once through cooling system disposes warm water in the receiving body. Its environmental impact is sometimes of concern and therefore the practice of this system has been under scrutiny. However there are different pros and cons for changing to circulating system. We discuss the issue;

Once through cooling system does not waste any water and all the water withdrawn from the source is returned. Circulating system using Cooling Tower looses a significant amount of continuous loss of water. For BTPS, this will be about 20,000 m3/day.

The lean season flow of Hugli (Ganga) river remains about 35000 cusec (source: from Farakka barrage discharge). The cooling water discharge is about 7.6 cusec. So even in lean season there is huge dilution available.

There has not been any report of ecological impact due to cooling water discharge. An earlier study by Prof T.M.Das, eminent ecologist and emeritus professor of Calcutta University, on impact of cooling water from Titagarh TPS, (it is about 30 km downstream on the river Hugli) found no significant result. However a detailed study on this aspect may be done.

9.5 Ash Pond Water

At present fly ash from Units1 to 4 is being collected dry and being stored in ash silo for further disposal. Fly ash from Unit 5 is sent to ash pond hydraulically as ash slurry due to problem in operation of the dry collection system. As this system will be renovated, fly ash from Unit 5 will be collected dry and stored in the silo. Only bottom ash will have to be sent to the ash pond. The present ash pond which was considered for all the five units will therefore have much excess space to deal with this new situation.

Considering 30% ash content and calorific value of 4900 KcaVkg (refer the coal characteristics in Chapter 5), the quantity of bottom ash from Unit 5 will be about 7 Tlhr. Yearly generation will be about 50,000 m3 from Unit 5 and total bottom ash load will be about 80,000 m31year. At present about 400,000 m3 of bottom ash (from all units) and fly ash (from Unit 5) are deposited at the ash pond. In future there will be only 20% of present amount will be disposed at ash pond.

I

SGS SGS India private Limited 98

Ash pond Water Treatment

llDEL

In view of the above it is suggested that the existing ash ponds shall be redesigned so that extra land from ash pond can be recovered and used for other purposes in the future. At present there are two ash ponds which are used alternatively. One ash pond may be taken out of the service. The other ash pond would be divided into two parts, one working and another as standby. The ash pond water outlet quality monitoring results (ref Chapter 3.0) show that the water quality is much within permissible level for disposal for Indian standard (TSS e l00 mgn; pH ~ 8 . 5 ) . Therefore the length of the ash pond keeping as it is at present, there will be a collection-cum-settling basin at the end of the pond and the clean water can be disposed or reused.

WBPCB has suggested in its compliance that ash water to be recirculated and reused. It is no doubt better to reuse the water for ash disposal again to reduce the water consumption. However as the ash pond is about 1.5 kilometers away from the boilers, it would require laying of pipes and pumping the water back. As river water is being used for ash transportation, if the ash pond outlet goes back to river again, it can be considered as recirculation without any energy use required for pumping. A part of the ash water is also used in the agricultural field. So the reuse of ash water may be reviewed.


Other wise the final settling tank at the end of the ash pond will be used as a sump for pumping the ash water back for reuse. As the ash pond is common for all the units, the total water quantity will be about 40-50 m3/hr. Settling tank can have 2 hours residence time.

Chapter 9

9.6 Plant and Township Sewage

Present arrangement for disposal of Township sewage has been described in Chapter 3.0. At present it is only collected in a sump and pumped to the agricultural field.

It has been decided jointly by WBPDCL & BTPS that a Sewage Treatment Plant (STP) shall be constructed in the township of BTPS, acting as a check point for the discharge of township sewage after meeting the stipulation of the WBPCB. A detailed project report (DPR) has already been prepared and the preliminary construction has been started.

In this STP, sewage from township will be collected in a sump from where the sewage will be pumped to the Cascade Aerator into multiple steps for aeration. From Aerator the sewage will flow by gravity to the oxidation ponds (two nos. oxidation ponds of 50% capacity each) for photosynthesis & stabilization of effluent. The overflow from stabilization pond containing BOD & suspended solids within norms prescribed by the Pollution Control Board will be discharged & reused as far as practicable for


pisciculture & horticulture. (Ref. Dwg. No. 2004008/PEJSK-05. Treatment Scheme for Sewage from Septic Tank of Township)

(a) The following are the basis of design for the proposed treatment facility jointly arrived by WBPDCL, BTPS & CES

Chapter 9

.IIocL

Design Flow Rate : 600 KL/day on 24hrs. basis i.e.25 Cu.M/hr. Influent & Effluent characteristics to & from the treatment facility.


9.7 Air Pollution Control

Parameters PH Suspended Solids, mg/l Oil & Grease, mg/l BOD, mg/l COD, mg/l

As discussed in Chapter 5.0, the two major sources of air pollution are emission from the boiler stack and fugitive emission from different points in coal and ash handling. The suggested interventions are given below.

Emission from Stack (Unit 5)

Inlet Concentration 9.5 200

20 80 200

Emission data from the stacks have been described in Sec 3.6 and 3.7. It was seen that to attain the stipulated emission limit of particulates of 150 mg/Nm3, it was necessary to inject ammonia in the ESP system. Monitored stack emission data usin B ammonia injection during the study done by us varied between 53 to 107.4 mg/Nm . During the last one year monitoring by BTPS, the stack emission values varied from 23 to 132 mg/Nm%s shown below. Considering the World Bank limit of SO2 and N02, the emission data shows no requirement of any intervention as those are always within the limit.

Outlet Concentration 7 to 8 50

8 20 150


Particulate emission from Stack Unit 5 (in mg/Nm3.)

Monthly BTPS During Present Study Monitoring monitoring April, 2006 23.16 Test 1 101 February, 2006 68.99 Test2 100 January, 2006 21.93 Test 3 53 September, 2005 70.17 Test 4 72 August, 2005 33.85 Test 5 87.7 July, 2005 39.56 Test 6 107.4 June, 2005 131.98 May, 2005 21.83 April, 2005 107.22 Average 57.63 86.85

-

The above data shows that due to injection of SPM the emission level stays much below the limit of 150 mg/Nm3. However it may be mentioned that the operators' goal is to limit the emission level below 150 mg/Nm3 as that is the required norm. But the data level shows that often the level remains much lower and average remains at about 57.6 mg/Nm3. The experience of CESC Ltd in Kolkata running similar injection system shows that they can fix the limit at 75 mg/Nm3 with this system (Refer Annexure 7). Now at BTPS the operators start to operate the ammonia injection system only when the opacity meter shows the emission level going over 100 mg/iVm3 and approaching 150 mg/Nm3. So the required level of 100 mg/Nm3 can be achieved.

However the present ammonia injection system should be modernised with automatic control system where the automatic injection of ammonia could be started at a set point of particulate concentration. This system is already available and needs to be introduced. The system operates as follows:


Automated ammonia injection system Pre- adjusted at equivalent to 1 ppm flow of Ammonia

When opacity of the flue gas crosses 80 gm/Nm3 first solenoid valve (Sl) will operate

Second solenoid valve operates on crossing of opacity 100 mg/Nm3. If Opacity crosses 120gram/Nm3 , third solenoid valve (S3) will come in operation Reverse operation will occur during decreasing SPM level due to action of

Ammonia.

Chapter 9

Issues about ammonia injection

However few other points have been raised about the ammonia injection method. It needs to be mentioned that Ammonia Injection process is also suggested by USEPA and discussed in details in ESP Training Manual (EPA-600lR-04-072), published in July 2004. (Refer Annexure 7).

I I I


One issue is about any leakage in the duct or ESP and subsequent impact. It has been observed during the study that final emission flow rate has increased due to leakage. Higher flow rate in ESP can lower its efficiency and form uneven flow regime. It may be mentioned that Ammonia is injected at a very low concentration of 2-3 ppm and it gets heavily diluted. So as such there is no danger in ammonia leaking from duct. Ammonia is considered mostly reacted with sulphur compounds and even unreacted ammonia from the top of stack gas will have no problem. Quantity of ammonium sulphate formed is so less to have any impact on the ash quality as such. Ammonium sulphate is a non-hazardous and non-toxic compound. No impact due to ammonium sulphate on downstream equipment has been reported or envisaged.

Though ammonia is a common gas used in the industries, handling of ammonia needs care. It is a toxic gas and can cause injury by inhalation or skin contact. At 500 ppm the impact is fatal. 0.5 ppm exposure can have acute feeling. Thus ammonia handling area should have good ventilation. Safety glasses and gloves for the operators are to be provided.

Chapter 9 -

Safetv instructions for Ammonia handling are


o Keep container in a well-ventilated place. o Keep away from sources of ignition. o In case of contact with eyes, rinse immediately with plenty of water and seek

medical advice. o Wear suitable protective clothing. o Wear suitable gloves. o Wear eye 1 face protection. o In case of accident or if you feel unwell, seek medical advice immediately

On-line Continuous Stack Monitoring

Besides there should be arrangement for on-line continuous monitoring of PM, S02, NOx and CO and it should be linked with control room and DCS.

Dust Suppression

Coal Stock Yard

As discussed before that there is no dust suppression system in Coal Stock Yard. Only dust suppression system is in operation at Coal unloading area. During summer season, the dust emission from the area poses problem to the workers and is an important component of occupational health.

ses SGS India Private Limited


It is therefore suggested to have

Pressurised water pipe line around the stockyard area from which connection points will be provided for sprinkling of water as required.

The stockyard area should have good house keeping. The wastewater will be disposed through Coal Stock Yard's storm water drain only.

Ash Silo

As described before in Chapter 4.0, dry ash is stored in silos and then disposed by truck for reuse. The process of transfer of dry fly ash to open trucks generates significant fugitive ash dust. The dust deposited on the silo area is washed and the wastewater is settled and then disposed. However some dust which gets dispersed in air causes air pollution and also impacts workers' health.

To prevent this it is suggested that only special covered bulk tankers with arrangement to connect hose from the silos directly should be allowed to collect fly ash.

9.8 Solid Waste

Major solid waste from thermal power plant is ash. At present the fly ash from the boiler for unit 5 is being mixed with water and the ash slurry is sent to ash pond. There is presently arrangement for dry ash collection system provided with conveying pipelines and silos. However the system is not operating. It is a hydroextraction type and could not be commissioned properly.

Dry Ash Extraction System

It is therefore suggested to provide a new negative pressure dry ash conveying system utilising the existing pipelines and the silos. The system should also have air pollution control system using bag filters to clean the conveying air.

Scrap Yard

As discussed before in Sec 4.7 that the plant lacks proper housekeeping. Scraps, used machinery parts etc are disposed here and there. A substantial area bordering the southern end of the plant is filled up with the scraps and the area is full of bushes. We suggest that this area (about 150 m x 50 m) be properly arranged as scrap yard.

[ SGS India Private Limited 103


The present scraps have to reorganised, the area has to be cleaned of plants and bushes and the whole yard should be fenced. There should be proper entry gate with signs. The area will be divided into several sections with roads in between and scraps should be stored in orderly manner with similar types stacked at same place. Please note that no hazardous material (acids, oil, gas cylinders etc) or hazardous wastes (used batteries, oil drums etc) will be kept in the scrap yard.

There should be a specific effort to dispose the scraps regularly so that space for new scraps is available.

Hazardous waste storage

Two major hazardous wastes in the plant are used batteries and oil drums often with residual oils and used oils.

A new hazardous storage area can be marked in one comer of the scrap yard for storing used oil drums and batteries. The area will be separated with fencing along with proper entry gate. It will have open paved yard for storing used oil drums in orderly manner. The paved area will have roof to prevent rainwater coming in contact with the oil. The area should be covered at the top so that rainwater does not fall inside. It should have a guard drain around. The water from that drain should pass through some settling pit before being discharged to storm water drain or can be led to the guard pond.

The used batteries should be stored inside a room in a building within the hazardous storage zone. The room should have tiled floor as there may be spillage of acid. The building will have another room for storing documents on all stored wastes and for official work for disposal of the hazardous wastes.

9.9 Noise Control

It has been shown in Chapter 3.0 that noise from the Turbogenerator is just above 90 dBA (92.3 - 92.99 dBA). As no worker is stationed continuously for 8 hours, it is within accepted level. However the noise during start-up of the plant has become a nuisance even for the local community as mentioned in Chapter 7.0. It is therefore very much urgent to mitigate this problem as an emergency basis.

Silencer facilities

It is suggested to install proper silencer facilities in the boiler system identifying the specific causes for high noise during start up. Generally this is caused by exhaust steam and silencers are required to dampen the noise. It should ensure that the noise

ss SGS India Private Limited 104

level outside the boiler area remains within 85 dBA. Noise level outside the plant premises should not have any impact from the boiler operation.


9.10 Laboratory

Chapter 9

The existing laboratory is meant for checking coal quality and water parameters required for boiler performance. It is not meant for any environmental monitoring. A separate laboratory dealing with environmental issues needs to be set up. The laboratory will supervise and carry out the environmental monitoring requirements of the plant. As this study suggests setting up a number of effluent treatment schemes alongwith a STP, a regular monitoring will be required to ensure the environmental performance.

The following basic instruments and accessories are suggested for setting up the laboratory.

Table 9.1 Laboratory Equipment Required for Environmental Monitoring

S1. No.

Hi h Volume Sam lerlRes irable Dust Sam ler 2 Sets Vacuum um with electric motor 2 Sets

4. Ammeter and Voltmeter 1 Set 5. Generator 1 Set

Equipment

1 Set I. 1.

$ c C SGS India Private Limited nn aaf

Quantity

Meteorology Automatic Weather station

6. 7. 8. 9.

1

1 1 1 Set Stack emission kit with necessary accessories Gas Liquid Chromatograph Orsat Apparatus Portable dust samulers

1 Set 2 Set 2 Set

All related chemicals, glass wares, pipettes, burettes etc required for analysis will also required. Manpower required for the laboratory is discussed in Chapter 8.0.

9.1 1 Social Intervention

Chapter 9 -

It has been discussed in Chapter 7.0 that there is a need to provide some social and environmental services to the affected community. Those can be


A regular air and noise monitoring schedule

Periodic Medical Check up camp

9.12 Capacity Building

Institutional capacity assessment has been detailed in Chapter 8.0. The gaps have been discussed there and the requirements have also been suggested. Specific interventions needed for that will be primarily of two types - one will need capital cost for installing some system and other is the operation cost for the system.

Major capacity building activities will be developing an Environment Management Cell and an Occupational Health Centre

Initial capital cost for Environment Management Cell will be required for

Developing an Environment Management Cell with dedicated space, computers, printers, office accessories etc. Developing a documentation centre on environment Developing the EMS for the plant and obtaining IS0 14000 Preparing an On-Site Emergency Plan



Operating cost will be required for

Appointment of required personnel Training of the personnel Maintenance and replace cost of office equipment Periodic environmental audit

Initial capital cost for Occupational Health Centre will be required for

Developing an Occupational Health Centre with dedicated space, computers, printers, office accessories etc. Developing a documentation centre on occupational health and safety Purchasing personal safety gears Purchasing equipment for medical facilities

Operating cost will be required for

Appointment of required personnel Training of the personnel Maintenance and replace cost of office equipment

A Summary list of all the major interventions are provided in Table 10.2.


Table 9.2 Summary of Interventions


1 ~ r . NO. ~ Interventions

Chapter 9

I 5 I

1 Eaualisation tank and Parallel Plate Interce~tor for effluent from Other Drains

1

2 3 4

1 6 1 Guard Pond I

Pump meters, connections to the control room and data acquisition system. a) Three (3) cooling water vertical mixed flow pumps of 9 5 0 0 ~ ~ 1 h r each b) 4 Nos. Raw Cooling water pumps of 2400 ~ ~ / h r . e a c h c) Two (2) nos. pumps of 100 M3/hr. capacity for service water d) Two (2) nos. D.M. water service pumps of 60 M3/hr. Coal Yard Storm water disposal using existing Oil pond Oil Unloading Area water treatment using equalisation tank, API separator Canteen wastewater treatment

7 I On -line pH monitoring system for Neutralisation pit 8 I Construction of facilities to reach CW outlet confluence with river for

9 10

monitoring activities Renovation and redesigning of existing wastewater disposal system Stack on-line monitoring system for PM, S02, NOx, CO Automatic control svstem for Ammonia Iniection

11 12 13

Developing an Environment Management Cell with dedicated space, computers, printers, office accessories etc. Developing a documentation centre on environment Developing the EMS for the plant and obtaining I S 0 14000 Preparing an On-Site Emergency Plan

J

Pressurised water pipe line around the coal stockyard area Dry Fly ash extraction system Scrap yard development

14 15 16

Hazardous waste storage facilities Silencer arrangement for boiler Capacity Building : Environment Management Cell

17

1 19 I Ash ~ o n d restructure and ash water collection sum^ 1

pp

Capacity Building: Occupational Health Centre Developing an Occupational Health Centre with dedicated space, computers, printers, office accessories etc. Developing a documentation centre on occupational health and safety Purchasing personal safety gears

- 18

Purchasing equipment for medical facilities Environmental Laboratory with all required equipment and instruments


Figure 9.1 Proposed Wastewater Treatment

I Boiler Blow Down L

CW Outlet

Dust suppression, Gardening

t

h . I

I Oil handling Area I , 4 A P I Separator CI

I

Misc Service Water P P I Guand Pond

I + TO stom Water I

Lab Water b

I Ash Pond I

1 Bottom Ash Ash Water Sump

Coal Yard

Ash Water Sump

Trench

h .

Oil Pond

b Canteen

h

A v

P

Storm Water

Screen

D

Recycled to Ash Water Sump

Ash Pond

- Sump

Oil Removal

API Oil Separator

Parallel Plate Interceptor

Schematic Layout Plan Not to Scale

All dimensions in meter

Holding 0 Separator

Guard Pond

Plant Waste Water Treatment

10.1 Introduction

10.2 Investment Budget


10.1 Introduction:

Investment Plan discussed here is based on the interventions proposed in Chapter 9.0. The costing has been done based on similar projects and past experiences. The prices are for the January 2008. However these are budgetary prices and therefore prices during implementation will vary to some extent depending on various factors including design specifications

10.2 Investment Budget

Budgeted cost break up is given below. Total cost is Rs. 350.1 million (Rs 35.01 crore, about $8.75million). About half the cost (5 1%) is for the dry fly ash evacuation system. Wastewater treatment including ash pond rearrangement will cost about Rs96 million, 27% of the budget.

Budgeted Cost

item Cost (Rs.) 1 Total I Pump meters, connections to the control room and data acquisition system. a) Three (3) cooling water vertical mixed flow pumps of 9500M3/hr each

c) Two (2) nos. pumps of 100 M3/hr. capacity for service water

b) 4 Nos. Raw Cooling water pumps of 2400 M3/hr.each

d) Two (2) nos. D.M. water service pumps of 60 M3/hr.

Each water flow meter with transducer and DAS will be approx. 2.0 lakh

Total 25 Lakhs

In Crores 0.25

I

~ f SGS India Private Limited

pond

Coal yard area and related area = 45,000 m2

1.75 Coal Yard Storm water disposal using existing Oil

Drain renovation Oil pond renovation

Cost of

Comprehensive Environmental Audit and Due Diligence Assessment of Chapter 10 the Bandel Thermal Power Plant

[Coal yard = 265 m x 150mJ The existing drains have to redirected to opposite direction to take advantage of Oil-pond to be used as settling basin. There are 3 surface drains 265 m long, 1 m wide and 1 m depth.

I I Oil Unloading Area

A flow of 27 m3 hour considered. During heavy rain there can be bypass. API separator and then to guard pond

Pond renovation 25 ~ a k h s

API Separator

Oil collection system Tanks, pipes etc.

1.5 Crore

Other Drains and ETP

I

Boiler Blow down - 15 m3/hr Laboratory - I m3/hr Surface drain - 2 m3/hr

This water can be collected in an equalisation tank, 8 hr holding time, 150 m3 size. Then passed through a Parallel Plate Interceptor and then led to Guard pond

Canteen Wastewater Treatment

It will consist of screen, holding tank, lime-alum mixing arrangement, final settling, sludge removal system etc. It is recommended to go for small package plant as daily flow is about 20m3lday

Guard Pond

Total flow will be about 20 m3hr from other drains and 8 m% from DM plant neutralising pit,. There will be intermittent flow from oil separator.

Tentative sizing of Guard pond- 48 hour residence - with design margin 1500 m3

Parallel Plate Interceptor Drains Holding pond

70 lakhs for equipment and 20 lakhs for civil construction

Excavation cost. 70L Piping, etc. 7.5 L

0.90

I I 1 I

- .

S02, NOx, CO b) Automatic control system for Ammonia

Injection

I I Realignment of storm water drains

Online pH monitoring at Neutralisation Pit Making a pathway to the CW outlet confluence

a) Stack on-line monitoring system for PM,

5 lakh

1 crore / 1

5 lakhs 15 lakhs

25 lakh

separate pumpinglpiping, sprinklers etc. total cost shall be Rs. 2.5 Crore

0.05 0.15 0.3

1 1 1

incl civil cost) -- Dry Fly ash extraction system

for erection, electrical and

I Dust suppression system in coal stock yard / Cost considering


2.5 1


control system (ash conveying pipeline and

-- Scrap Yard Development 50 lakhs , mostly civil cost of 0.5

cleaning the land, building I fencing and internal road

I Hazardous waste storage ' / 50 lakhs for floor paving, ( 0.5 I

I building construction etc Silencer arrangement for boiler

Capacity Building Occupational Health Centre

Developing an Occupational Health Centre with dedicated space, computers, printers, office accessories etc. Developing a documentation centre on occupational health and safety Purchasing personal safety gears Purchasing equipment for medical facilities

0.5

Capacity Building Environment Management Cell

Developing an Environment Management Cell with dedicated space, computers, printers, office accessories etc. Developing a documentation centre on environment Developing the EMS for the plant and obtaining IS0 14000 Preparing an On-Site Emergency Plan

Hard wares + personnel protective gears 2.5 crore.

3 lakh

Civil cost excluded 0.5 lakh

5 lakh

5 lakh

Other costs 0.5 Lakhs

I I 1 I Ash pond restructuring and settling basin 1 2.0 crores 1 2.0

Environmental Laboratory With all required equipment and instruments

I construction 1 Total 35.01

20 Lakhs

%$" SGS India Private Limited

Annexure 1: Previous Monitoring Data

Available Data - Stack Monitoring done by WBPCB


Available Data - Stack Monitoring done by laboratories authorised by WBPCB

Unit - I

April, 2007 March, 2007

Unit - IV I PM Unit -rSo2 I Date I PM I SO2 I NOx I PM 1 SO2 I NOx 1 PM I SO2 I NOx I PM I SO2 ( NOx

Unit - I1

December, 2006 November, 2006 October, 2006 September, 2006 August, 2006 July, 2006

Unit - I11

--- 60.53

46

May, 2006 1 48.25 1 509.21 1 149.71 1 26.04 1 721.92 April, 2006 1 118.69 1 426.1 1 112 ( 41.25 1 357.5

1 20 36.53 22.21

141.52 31.35 95.85

March, 2006 February,2006 January, 2006 December, 2005 November, 2005

780 611.56

210.83 1 145.74 1 544 1 167.57 102.01 1 50.82 1 259.47 1 76.23

October, 2005 --

September, 2005 August, 2005 July, 2005 June, 2005

675.05 688.5

630.61

512 694.4

413.33

24.93 132.42 89.75 26.15 35.28

915.6 565.14

63.93 124.7

36.61

22.47

21.03

447.02 279.79 340.23

280.2 254.1

138.04

722.49 252.63 242.02 237.23

240

80.82 65.57

741.12 236.93 I 23316 I I

243.48

237.04

231.58 May, 2005

95.07 137.66

135.64 31.83

117.87

412.33 21 8.39

350 342.22 33 1.43 331.43

Note: All Values in m g / N ~ 3 27.23

707.5 682.67

131.86 412.38

331.43

331.82

- 317.44

14.7 229.51 321.07 20.21 230.4 321.07 21.38 229.51 321.07 66.59

614.4 444.27

620 582.4

133.35 24.12 32.25 39.66

250

645.3 574.75

44.77

20.8 30.07 24.36 26.02

241.51

-

276.08 31 1.71

336.51 310.83

246.91 257.14 237.23

240

349.93

188.94 80.08

520 1173.75

243.48

258.58 260.46 237.04 236.06

339.6

126.4 42.84

32.6

98.07 101.74

338.96 359.68 331.43 331.43

21.83 107.22

736 632.47

29.95

331.43

360.71 360.71 331.82 328.54

40.9 2.;;.;;1

901.49 522.24 787.92

487.62 381.55

35.7 21.01

23.06

709.06 580.52

691.2

24.19

57.26 24.41 49.34

132.95 241.51

477.07 243.29 414.09

310.42 160.7

466.94 237.04

228.57

44.52 43.67

230.07

248.54

248.88 223.25 237.04 246.15

346.98

131.1 1 80.65

143.46 135.92

142.16 331.82

324.44

688 676

147.9

13.63

342.22

350 310.06 331.82 339.6

620.18 609.35

515.71 539

445.71 635.24

59.44

13.55 24.55 34.37

244.16 278.56 ----

235.56 230.75

822.85

230.45

28.1 1

110.5 49.89

1643.52

257.14 251.97

250

317.44

274.7

247.1

220.69 224.56

-I

347.97

359.68 352.7

345.03 342.22

303.17 310.07

68.99 21.93

268.01 308.35

70.17 33.85 39.56

13 1.98

266.67 241.9

246.15 232.26


Available Data - Ambient Air Quality Monitoring done by laboratories authorised by WBPCB

Month, Year

April, 2007 March, 2007 February,2007 December, 2006 November. 2006 October, 2006 September, 2006

Ann Avg 1 168.18 1 86.33 ( 11.26 1 32.87 / 190.07 1 98.11 1 15.69 1 39.46 1 221.17 1 119.90 1 18.35 1 39.45 Max 1 235.82 1 120.9 1 15.57 1 40.35 1 275.16 1 138.65 1 26.5 1 52.78 1 310.5 1 148.01 ( 28.72 ( 54.5

Note: All Values in pg/rn3

Gate No.4

163.14 235.82

~ u g u s t , 2006 July, 2006 May, 2006 April, 2006

SPM ----- 142.17 151.32

171.51 135.63

180.46

Gate No.3

82.62 120.9

151.72 164.5

168.46 185.2

RPM 61.73 73.31

CHP Plant

71.66 51.03

101.8

1 SPM 177.33 164.5

SPM 180.5 210.7

9.07 14.79

SO2 7.57

8.5

RPM - 90.5 81.5

I SO2 10.47 9.44

9.53 10.81

12.5 9 0 . 1 8 10.5

NOx 24.5 26.5

NOx 32.5

30.46

RPM ---- 94.85

117.89 30.48 35.67

31.75 35.72 35.67 40.35

101.85 92.75

101.77

31.78 30.7

38.5

11.5 13.5

15.57

SO2

113.46 224.81

135.76 148.46 218.47 210.36

9.44 11.5

212 ( 210.46

275.16

30.46 35

90.83 87.21

102.63 115.36 120.67 112.48

73.34 66.02

138.65

10.47 11.51

14.5 20.5

22.85 20.67

10.1 15.59

26.5

30 32.8

42.78 52.78 52.67 48.28

143.44 310.5

30.7 ( 148.7

2 4 2 . 7 5 268.5

267 .43 258.15 1

55.95

118.14

1 38.63 (

42.5

88.12 148.01

230.58

171.62 135.85 140.85 145.81 140.64

6.08 23.99

9.06 18.6

21.5 24.67 28.72 26.75 24.85

34.45 41.78

54.51 41.85 45.87 40.8

36.72 1

I

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q q q q q o o o .

w w F " ~ " w m m " ~ ? ~ w w ~ w ~ m w ~ * ~ ~ m O ~ P w ~ m ~ ~ m m Q w w O a F m m m m m d m m m d m m d

F F F F Q Q a W W Q Q a W Q Q W W m m m m m m m m m ' m

8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 ?q????????????q????q???????

o ~ m - m w ~ m m m m o ~ ~ G o o & ~ V ; V ; ~ ~ ~ ~ ~ o

F F F F w a Q w a w Q a a w Q a m m m m m m m m m m m

8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 ? q ? ? ? q ? q q q q q q ? ? ? ? q ? ? ? ? v * ? ? ?

& ~ G ~ & ~ ~ & m w z g ~ w d w - b w - - - ~ F F m m m m m m m m m m o

qz?zCF;zYfP?2F;Y?g

m m - z z " " w w w a

d d d d d d d d d d d d d

m m m m m m m m m m m m m

d d d ' d d d d d d d d d I d a n a a n n a n a a a a a m m m m m m m m m m m m m

w m - - F - o o m m - m w m m m m m m m m m m m m m

o m m m m m o m m m m m m

99999999

9 9 9 ~ 8 8

m m m m


Available Data - CW Outlet Water Analysis done by WBPCB

Annexure 1 : Previous Monitoring Data

Available Data - Ash pond Outlet Water Analysis done by WBPCB

Available Data - Township Sewage Outlet Water Analysis done by WBPCB

Amexure 1: Previous Monitoring Data

Available Data - Township Sewage Outlet Water Analysis done by WBPCB

30.08.05 28.07.2005 21.06.2005

26.05.2005 26.04.2005

7.8 -- 7.7 7.68

7.67 7.65

38 6 18

2 166

38 34

39.6

9.61 85.28

A 6

14.56 Not done 6.5

BDL <1

<1' 1.83

ANNEXURE 2 RESULT OF MONITORING /

ANALYSIS DONE DURING THE STUDY

Annexure 2: Results of Monitoring1 Analysis done during the study

Environmental *Wefts

Process Effluent

Parameters

PH

Unit Day 1 (22.08.2007)

Neutral isation

7.46

Day 2 (23.08.2007)

Coal Handlin Sample

Day 3 (24.08.2007)

Ash Pond

7.62

Ash Pond

8.09

Neutral isation

8.09

Neutr alisati

7.6

Coal Handli Sampl

Coal Handli Sample

Ash Pond

7.1

Annexure 2: Results of Monitoring 1 Analysis done during the study

Treated Process


Environmental Aspects

Sewage Effluent from plant and

colony

Environmental Aspects

Parameters

Suspended

Solids BOD

COD

Oil & Grease

PH

Parameters

Alkalinity

Ammonia(as

NH3 - Free)

B.0.D @ 27°C

for 3 days

Day 2 (23.08.2007)

River - Downst 107.84

0.4

5.17

Day 3 (24.08.2007)

Unit

mgil

mgil

mg/l

mgil

Unit

mgil

mgil

mg/l

River Down 87.3

4.8

4.83

River - Upstre 97.57

2

5.83

Pond near 179.73

0.4

4.13

River - Upstrea 82.16

2

2.25

Day 3 (24.08.

18

2.64

17.14

BDL

(DL -

2.0) 7.46

Day l (22.08.

18

4.44

26.43

BDL

(DL -

2.0) 7.55

Pond near

87.3

0.2

4.13

Day 2 (23.08.

20

3.63

23.52

BDL

(DL-

2.0) 7.59

Day 1 (22.08.2007)

River - Downst 90.38

0.4

4.19

River - Upstrea

92.43

0.4

3.81

Pond near 188.97

0.4

3.75

Annexure 2: Results of Monitoring / Analysis done during the study

Surface WaIer Quality

4 . 0 2

6.1

0.2

0.14

4 . 0 5

4.78

16.74

<0.001

<0.05

4 . 5 0

Unobje

ctionab

le

<0.02

5.6

0.87

0.38

<0.05

12.43

43.51

<0.001

<0.05

<0.50

Unobje

ctionab

le

Copper

Dissolved

Oxygen Fluoride

Iron (a5 Fe)

Lead (as Pb)

Magnesium (as

Mg) Magnesium

Hardness (as

Mg C o d Mercury

Nickel

Nitrate (as NO3)

Odour

<0.02

6.3

0.16

0.14

<0.05

4.78

16.73

<0.00

1 <0.05

<0.50

Unobj

ection

able

mgA

mgil

mgil

mgA

mgil

mgil

mg/l

mgil

mgll

mgil

4 . 0 2

5.6

0.53

0.27

4 . 0 5

14.59

51.06

<0.001

4 . 0 5

4 . 5 0

Unobje

ctionabl

e

<0.02

6.1

0.49

0.14

<0.05

6.69

23.42

4 .001

<0.05

0.89

Unobje

ctionab

le

<0.02

6.3

0.25

0.14

<0.05

5.26

18.41

4.001

<0.05

0.93

Unobje

ctionabl

e

<0.02

6.1

0.21

0.14

<0.05

8.9

31.15

4 . 0 0

1 4 . 0 5

0.58

Unobj

ection

able

<0.02

6.3

0.2

0.14

4 . 0 5

4.78

16.73

<0.001

4 . 0 5

4 . 5 0

Unobje

ctionab

le

<0.02

5.6

0.71

0.47

<0.05

11.48

40.18

0.003

<0.05

<0.50

Unobje

ctionab

le


-

SO,)

BDL

(DL-

2.0) 7.85

<0.05

4 . 2 5

4.9

4 . 0 1

7.13

<0.02

4.65

0.2

4.84

BDL

(DL-

2.0) 7.67

4 . 0 5

<0.25

5

4 . 0 1

8.84

~ 0 . 0 2

4.59

0.15

11.56

BDL

(DL-

2.0) 7.89

<0.05

1.79

15.15

<0.01

16.6

4 . 0 2

29.47

1.02

22.27

Oil&Grease

PH

Phenolic

Compounds

(AsC6H50H)

Phosphate(as

PO,) Potassium(as

K) Seleniunl (a5

Se) Silica(as SiO* -

Reactive) Silver

Sodium (as Na)

Sodium

Absorbing Raio Sulphate (as

mgn

mgn

mg/l

mg/l

mgn

mgn

mgn

mgn

mg/l

BDL

(DL-

2.0) 8.12

<0.05

<0.25

4.77

4 . 0 1

7.72

~ 0 . 0 2

4.74

0.24

4.88

BDL

(DL-

2.0) 7.8

4 . 0 5

<0.25

4.46

4 . 0 1

9.51

<0.02

4.43

0.21

17.22

BDL

(DL-

2.0) 8.6

<0.05

<0.25

4.73

<0.01

8

<0.02

4.51

0.21

3.81

BDL

(DL-

2.0) 8.82

<0.05

1.63

13.09

<0.01

13.32

4 . 0 2

28.06

0.8

17.23

BDL

(DL-

2.0) 7.74

41.05

0.32

5.52

<0.01

9.34

<0.02

4.52

0.22

10.03

BDL

(DL.-

2.0) 8.27

4 . 0 5

1.57

14.75

4 . 0 1

14.78

<0.02

28.15

1.11

21.11


Ground Water Quality (As per IS 10500) near Ash

Pond

Magnesium(%

Mg Manganese ( a

Mn) Mercury(% Hg

) Nitrate (as NO3)

Odour

Mineral Oil

PH

Phenolic

Compounds(as

C6H,OH)

mgA

mgA

mgil

mgA

mgil

mgA

21.04

0.15

4 .001

<0.5

Unobje

ctionab

le BDL

(DL=

0.01) 7.34

4.001

21.52

0.14

4.001

4 . 5

Unobje

ctionabl

e BDL

(DL=

0.01) 7.1 1

4.001

20.56

0.12

<0.001

4 . 5

Unobje

ctionab

le BDL

(DL =

0.01) 7.13

4.001


Residual Free

Chlorine Selenium

Sulphate

Taste

Total Dissolved

Solids Total Hardness

(as CaCO,)

Turbidity

Zinc (as Zn)

mg/l

mg/l

mg/l

mg/l

mg/l

NTU

mg/l

<0.10

<0.01

3.08

Agreea

ble 422

295.2

2.1

0.07

<0.10

<0.01

3.37

Agreea

ble 416

293.23

<0.5

0.1

<0.10

<0.01

3.09

Agreea

ble 468

291.26

2.8

0.08


Environmental

Ambient Noise


Environmental


Lead (a$ Pb)

Moisture

Content OrganicCarbon

pH Value( 1:5 w/v aqueous Porosity

mg/kg

%

%

%

16.45

35.19

0.13

7.07

45.41

26.12

40.49

0.14

7.29

46.48

19.57

30.61

0.14

7.3

43.44

15.05

40.53

0.17

7.11

52.5

16.23

30.52

0.16

7.28

44.69

25.47

43.08

0.18

7.57

51.31

Annexure 2: Results of Monitoring I Analysis done during the study

Zinc(aa Zn)

Mercury

mgkg

mgkg

60.21

0.64

104.75

1.55

62.6

0.84

68.72

c0.50 c0.50 0.93

Annexure 2 : Results Of Monitoring /Analysis Done During T h e Study

Result Sheet For Esp Efficiency Measurement At Btps

6 c

g .Y O

w

99.35

99.46

98.40

96.92

97.66

99.02

99.07

98.95

99.65

% Moisture

(vlv)

10.0

11 .1

10.0

11.1

8.9

10.0

8.9

10.0

8.9

9.01

9.8

10.1

9.1

9.8

9.1

9.8

10.1

10.8

%

0 2

(vlv)

9.0

8.4

9.0

8.4

8.2

7.8

8.2

7.8

8.8

8.2

7.8

7.0

8.0

7.2

8.0

7.2

9.2

7.6

Load (MW)

5 6

56

5 1

5 1

5 1

37

182

182

190

Dust Load

I l l mg I NM3 18.6 g / NM3

81 mgl NM

16.551 NM

291 mg I N M ~

20.1 g I NM3 1105 mg/ NM3

39.651 NM

570 mg I NM3 27.7 g l

NM3 181 mg 1 N M ~ 20.1 g l

NM3 206 mg 1 NM3 25.8 5 /

NM 228 mg I NM3

25.3 g l NM3

107 mg I NM3 34.6 g l

NM3

Velocity (mk)

18.04

15.19

18.04

15.19

21.34

20.20

21.34

20.20

17.8

16.22

11.04

10.39

22.74

19.26

22.74

19.26

22.52

19.68

No. of fields

in service

414

414

414

414

316

316

12/12

12/12

12112

Unit

Unit #I

Unit #3

Unit #4

Unit #5 A -LHS

without NH3

Coal flow rate

( T h )

36

36

3 3

33

33

24

118

118

123

No. of mills in

operation

313

313

313

313

313

213

515

515

515

E

.a - O

S

O/L

I/L

O/L

YL

O/L

I/L

O/L

UL

O/L

I/L

O/L

I/L

O/L

I/L

O/L

I/L

O/L

YL

* M

I

2

I

2

1

2

1

2

3

Gas

( m 3 W

473442

446221

473442

446221

560047

530129

560047

530129

483850

440901

300096

282427

389673

349453

389673

349453

385903

357074

Temp. (OC)

176

182

176

182

154

169

154

169

169

184

143

153

141

156

141

156

139

154

Date

1 61 10107

1 31 10107

12/10107

13110107

141 1 0107

2211 0107

Flow

(Nm3h)

275726

252632

275726

252632

347160

314480

347160

314480

290140

255666

191351

175515

248926

21 3769

248926

213769

243335

215851

% C02 (vlv)

11.0

11.6

11.0

11.6

11.6

12.2

11.6

12.2

11.0

11.6

12.0

12.8

11.8

12.8

11.8

12.8

10.8

12.4

Time

11:25

12:15

17:OO

1750

16:30

12:15

19:lO

1955

18:OO

'n

2 Q\

1

*

F

z z g z *

w

' n F * *

w ' n w

0

2 Q\

C

k 9

.- 5 a a 0 9 c 0 a .I? V) - Q c

c .- s C .- c

g V) C - 2 al K . . hl

?! 3 X al c c a

r z " r $ i z w'm

Q \ - * m * m

m

1

2

w ? Q\ Q\

alp-

w

" -

M , 1 E z 'n

m

---------

M%

--------

F

0 \4 Q\ Q\

09

2

1 1

~ z S ? ; z g z n z * z i

* 2

- 2

s

2 1

2

E 3 3

BTZ C1

* ? Q\ Q\

= = $

-

1 1

w

F 3 3

3

w 3

'n T

2 1

2

2 . . - -

m

2 3 g ~ g ~ ~ m w m w m m - ' n - ' n - ' n o

: ~ z 2 z ~ z z ~ C 1 N N N N N N N N N N

m + w w w w ' n m m w m G ~ ~ ? % ? % Z %

m m m m m m m m m m m m m m m m m m m m

w 'C! Q\ Q\

2 2 2

E z M , z f z g m Z 4 z

Q \ C 1 - C 1 - F w * C 1 * C 1 W o C 1 * C 1 * C 1 * *m*m-'nmzgz~2sWsggg

z - is----

m 2

s

2 a - 0 0 2

'

0

2 Q\

w * w ~ ~ ~ ~ ~ m O w m w m w " w

w 3 ? z Q \ ' n Q \ ' n w ' n w F w F m F

X?""zgg-

$"""Z=?X"S"

'n \4 Q\ Q\

g z $ z ~ z ~

M, E z , 2 5 5 2

'n 2

C1 z

s

2 1

2

2 . . - -

1

- * m w m w - m m m m m ' n w

F ' n F ' n ' n r n * W * W * W

s 3 - - 2 = - 3 - - - 3 - 3 3

'n 'C! Q\ Q\

r~vlyg

-------

2 -

C1 w 3

s

2 1

2

'n CT! 'II

-

2 6 Q\

M,

~~=?~~

-

w 2

* z

s

2 a - 0 ?! Q\

2 w 3 - -

1

EZFE g ? $ z

C1 2

s

2 1

2

3 z

- +

~ m ' n m * m * o - w * w * 3 W F m F m Q \ m o Z 2 Z 2 2 2 2 2 2 2 2 2 Z 2 2 2 2 2 2 2

C1 z

'n T

2 1

2

0 0 2

"! 2

-

C1 3 w

s

2 1

2

0 ?! F 3

- 2

7

- C1 2

s

2 5 'n 0 2

2

s?09'

2 7 2

S s $ g $ g s z -

m 2 2 2 2 2

7

\4

2

" 9

2 2

2 3

Annexure 2 : Results Of Monitoring 1 Analysis Done During The Study Flow rates of Unit Nn. V

~ - - - - ~.

Without NH, With NH3

Efficiency of ESP & Emission of Unit No. 5 I Efficiency, % I Emission, Kg1 hr. I Emission, mgl ~m~

Without Ammonia Test 1 Test 2 Test 3 With Ammonia Test 1 Test 2 Test 3

Note: * for test 1 & 2 flow measurement done once, dust load measure twice.

Test 1 *

225.2 160.2 143.4

72.0 87.7 107.4

98.97 99.1 7 99.42

99.73 99.68 99.51

Test 2* Inlet

222.6 158.3 140.9

7 1.4 86.9 105.5

Test 3

m 3 / h r 1370598 1401987

Outlet N m 3 / h r 838208 851436

m 3 / h r 1551837 1571371

Inlet N m 3 / h r 988427 991 126

m 3 / h r 1370598 1401987

Outlet Inlet Outlet ~ m - ' / h r 838208 851436

m 3 / h r 1551837 1571371

m v h r 1407612 1400173

m 3 / h r 1557663 1547723

N m 3 / h r 988427 991 126

N m 3 / h r 850135 852254

N m 3 / h r 982437 981976

Annexure 3 : Fire Fighting Details

Fire protection from Fire Hydrant svstem IPH & OPH of various places.

1 - 5 Units

'B' Category Power Stn. (Area - 4 Lack, 14 thousand Sq. M.) Fire fighting system at B.T.P.S.

Fire Hydrants

1-4 Units. 1 No. Elec. Driven hydrant pump 2000 GPM at 7 kg. Pressure. 1 No. Gasolin Engine for power failor. 28 No.s hydrant riser landing valves. & hydrant posts covered IPH (1-4 Units) and coal yard section of CHP Both inside Power House inter-connected by two hydrant main. 5' Unit 1 No. Elec. Driven Fire Hydrant Pump delivering 1500 GPM at 7 kg. Pressure. 1 No. Diesel Engine out of order. 1 No. Mulsifire Pump also used at for fire fighting. 58 No.s hydrant post & hydrant riser landing valve for IPH (5' Unit), Main Store, Switch Yard, rest portion of CHP etc. All fire hydrant checked by flow testinglrunning testing weekly.

Mulsifire Pump Mulsifire system now not working condition due to some technical defect and being repaired. Water tender or foam tender not available at BTPS Fire Safety Cell.


Manning Pattern 1. Gr. I Fire Controller - 1 Duty hrs. 8 AM to 12 Noon, 2. Gr. I Fireman - 1 1-30 Hrs. to 5-30 PM and 3. Technician - 3 2-00 PM to 10 PM 4. Contract Labourer - 3

Fixed Fire Fighting installation (portable) 150 capacity mechanical foam extinguisher 14 No.s 50 Ltr. Capacity mechanical foam extinguisher - 24 No.s 9 Ltr. Capacity mechanical foam extinguisher - 120 No.s 50 kg. Capacity dry Power extinguisher 5 No.s 25 kg. Capacity dry Power extinguisher 10 No.s 10 kg. Capacity dry Power extinguisher 25 No.s 5 kg. Capacity dry Power extinguisher 38 No.s 18 kg. 22.5 kg. Capacity C 0 2 extinguisher 12 No.s 7 kg. Capacity C 0 2 extinguisher 42 No.s 2kg. & 3kg. Capacity C 0 2 extinguisher 47 No.s 91t. Cap. Water C 0 2 extinguisher 10 No.s

Total No. of fire extinguishers placed at IPH and other Deptt. - 356 No.s All fire extinguisher checking regularly / monthly. We are using two classes of dry chemical power.

1. MAP base (50%) dry powder (ABC) 2. Orginary dry powder (BC)

Accessories

1. Delivery Hose 2.5" = 75' & 100' each 2. Foam making branch 3. Short branch pipe 4. Diffusive branch pipe 5. Bunker branch pipe 6. Deviding breeching (control type) 7. 3% mechanical foam for hydrant used in 20 Ltr. Jar.

Proposal at R&M Div. For purchasing Diesel Engine for 1-4 Units Pump Intake.


Sl. Name of the Section No. Location of Fire Extinguisher

1. Boiler & Turbine floor (Open. Floor)

2. Mezz. Floor(R) 1-4 Units 3. Ground Floor(R) 1-4 Units 4. Boiler & Turbine floor (5Ih Unit)

5. Mezz. Floor (5'h Unit) 6. Ground floor (sth Unit)

7. 6KV Room (51h Unit Gr. floor) 8. C.A.M.Office (51h Unit Mezz. Flr.)

\ -

9. 3KV Room (1-4 Unit Mezz. Floor) 1 0 . 4 1 6 ~ . ~ o o m (1-4 Unit Gr. Floor) 11. Coal Bunker (I -4 Units) 12. Coal Bunker & Motor House

(51h Unit 6'h floor)

15. Adrnn. Building 16. Chem. Laboratory 17. Service Pump House 18. D.M.Plant (Running Unit) " *

19. D.M.Plant (5th Unit) 20. ESP Control Room (I -5 Units) 2 1. Coal Handling Plant (CHP) 22. AuLomobile Repair Shop 23. Work Shop 24. PetroVDiesel Filling Stn. 25. Main Store 26. 5" IJnit Store 27. G.S. Buildg. 28. Diesel Generating Plant

Remarks C 0 2 Extinguisher Dry Chemical Powder Extinguisher Mech. Foam Extinguisher

Mech. Water

Chem. Foam


Room 34. Ash Water Pump House (5Ih Unit) 35. Fire Safety Cell

2

1

29. Township Elec. Supply 30. BTPS Hospital 3 1. LPG Godown 32. BTPS Recreation Club 33. BTPS Canteen & LPG Supply

1

- 1 120

2 2

2

2

3 1

-

- -

- 24

1 2

2

1 +2 1

2

14 1 10 2 1 6

2 38 25 2 10 5

2 47

1

42 13 Total=359 P

'12' .4

' \ a Y&,* 1 \ ,

B a l e 1 Th<.rmal I qwsr Stat ion l'r A i a a h A ussw* DUP 8k,

s h - m - m e *ambitarlSOI-

I

Thi. refer. t o your nrmo NhSR P & AD/ *all 197 d r k d m f l m i a l M a p r r b d w-t& h - 1 4 -

r r r m m t n f i t w a r S P r a t l l r s P r 1 am tetlm 8

Terrtatlve progxam for w e u . b d - i t M - - r g l . L d f r a rakumy, am*.

nuther, &U filL. to - artt uvep SqJSat foe the f e thme irtrtd af -b- L l a t i a a of 0% oo -4 C -93. weua amlamiat or f l y aeh i m a regular t*Vng e u t4 .wsatr

In vicar of & p p i s i m n a i a a . u 8tated &me, we will be grateful Lf yOP -J l e t w know your viw and aanasrrla t ~ a r d r r of-^

M P J ~ rob ~n~urrvu -srodrwl ~0q61q 411- w1JnO2 01 101 w u3a9 p r y e ~ o q ~ q114l P ' 1 1 1 ~ ~edtd. pur d:" i 1

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Annexure 5 : Standards Related To Thermal Power Stations

Standards For Liquid Effluents

I source I Parameter I Concentration not to exceed. 1

1 through cooling system) Temperature*

Free available

Boiler Blowdown

Cooling Tower Blowdown

Not more than 5 ' ~ higher than the 1 intake

Chlorine Suspended solids Oil & grease Copper (Total) Iron (Total) Free available Chlorine Zinc Chromium (Total) Phosphate Other corrosion inhibiting materials

As pond effluent

1 .o 0.2 5.0 Limit to be established on case by case basis by Central Board in case of Union Territories and

PH Suspended solids Oil & Grease

State Boards in case of States 6.5 to 8.5

* Limit has been revised Source: EPA Notification [S.O. 844(E), dt. 191h NOV; 19961

Temperature Limit For Discharge Of Condenser Cooling Water From Thermal Power Plant

A. New thermal power plants commissioned after June 1,1999. New thermal power plants, which will be using water from rivers/lakes/reservoirs, shall install cooling towers irrespective of location and capacity. Thermal power plant which will use sea water for cooling purposes, the condition below will apply.

B. New projects in coastal areas using sea water. The thermal power plants using sea water should adopt suitable system to reduce water temperature at the final discharge point so that the resultant rise in the temperature of receiving water does not exceed 7 ' ~ over.and above he ambient temperature of the receiving water bodies.

C. Existing thermal Power plants. Rise in temperature of condensor cooling water from inlet to the outlet of condenser shall not be more than 1 O'C.

D. Guidelines for discharge point: 1. The discharge point shall preferably by located at the bottom of the water

body at mid-stream for proper dispersion of thermal discharge. 2. In case of discharge of cooling water into sea, proper marine outfall shall be

designed to achieve the prescribed standards. The point of discharge may be selected inconsultation with concerned State AuthoritiesINIO.


3. No cooling water discharge shall be permitted in estuaries or near ecologically sensitive areas such as mangroves, coral reefslspaning and breeding grounds of acquatic flora and fauna.

Source: EPA Notification [GSR 7, dated Dec. 22, 19981

Thermal Power Plant: Emission Standards

* Depending upon the requirement of local situation, such as protected area, the State Pollution Control Boards and other implementing agencies under the Environment (Protection) Act, 1968, may prescribe a limit of 150mglNm3, irrespective or generation capacity of the plant.

Source: EPA Notification [S.O. 8(E), dt 3rd Jan; 19831

Generation Capacity Generation Capacity 210 MW or more Generation Capacity less than 2 10 MW

Thermal Power Plants: Stack HeightfLimits

Pollutant Particulate matter - do -

Emission limit 1 50mglNm3 350mglNm5

Generation Capacity 500 MW and above 200 MWl210 MW and above to

I I of SO2 in kghr, and H is Stack height I

Stack Height (Metres) 275 220

Less than 500 MW Less than 200 MWl210 MW

I in metres. Source: EPA Notification

H=14(Q) 0.3 where Q is emission rate

[G.S.R. 742(E), dt. 3 0 ~ Aug; 19901


GENERAL STANDARDS FOR DISCHARGE OF EFFLUENTS

$ All efforts should be made to remove colour and inpleasant odour as far as practicable. @ 90 survival of fish after 96 hours in 100 effluent. * For cooling water effluent 10 above TSS of influent. & (a) Floatable solids 3 mm, (b) Settleable solids 850 micron. @


GENERAL EMISSION STANDARDS [AS PER ENVIRONMENT (PROTECTION) RULES, 19861

I. Concentration Based Standards 1 SN 1 Parameter 1 Standard (mg/Nm3) 1

1 2 3

11. Equipment Based Standards (For dispersal of sulphur dioxide, minimum stack height limit is

4 5 6 7 8 9

Particulate Matter (PM) Total Fluoride Asbestos

150 25 Fibres : 4 noslcc

Mercury Chlorine Hydrochloric acid vapour and mist Sulphuric acid mist Carbon Monoxide - Lead

accordingly prescribed below)

I > 2001210 and ~ 5 0 0 I I 1 220 1

Dust : 2 m g / ~ m 3 0.2 15 3 5 50 1 max (vlv) -

Power Generation

Capacity (MW) 2 500

I H=14Q 0.3

Note : H= Physical height of the stack in metre

Steam Generation

Capacity(Th)

25 to 30 > 30

Q= Emission rate of SO2 in kghr

Coal Consumption

( ~ ~ l d a ~ )

105 to 126 > 126

Minimum stack Height Limit

(m) 275

27 30 or using ~. 1


Notes: 1. No exposure in excess of 140 dB peak sound pressure level is permitted. 2. For any peak sound pressure level falling in between any figure and the next higher or lower

figure as indicated in column 1, the permitted number of impulses or impacts per day is to be determined by extrapolation on a proportionate basis.

PERMISSIBLE EXPOSURE LEVELS OF IMPULSE OR IMPACT NOISE FOR WORK ZONE AREA

[AS PER MODEL RULES OF FACTORIES ACT, 1948 }

PERMISSIBLE EXPOSURE IN CASE OF CONTINUOUS NOISE FOR WORK ZONE AREA

PEAK SOUND PRESSURE LEVEL IN dB

140

Notes : 1. No exposure in excess of 115 dB(A) is to be permitted. 2. For any period of exposure falling in between any figure and the next higher or lower figure as

indicated in column 1, the permissible sound pressure level is to be determined by extrapolation on a proportionate basis.

PERMITTED NUMBER OF IMPULSES OR IMPACTS / DAY

100

[AS PER MODEL RULES OF FACTORIES ACT, 19481

I

TOTAL TIME OF EXPOISURE (CONTINUOUS OR A NUMBER OF SHORT TERM EXPOSURES) PER DAY. IN HOURS

PERMISSIBLE SOUND PRESSURE LEVEL IN dB(A)

A M ~ x u ~ ~ 5 : Standards Related To Thermal Power Stations

NATIONAL AMBIENT AIR QUALITY STANDARDS

I I I I I- Ultraviolet Fluorescence 1 24hours** 1 120up/m3 1 8 0 u d m 3 I 3 0 u d m 3 I

Method of measurement

I I I Areas I

Pollutants

Volume

Time-weighted average

Concentration in ambient air

- Improved West and Geake

Pxides of' vitrogen as 1(NOx) 'suspended Particulate b atter (SPM) I

Industrial Areas

Annual Average*

Annual Average*

nnual Arithmetic mean of minimum 104 measurements in a year taken twice a week 24 hourly at *

values should be met 98% of the time in a year. However, 2% of the time, it may

I 60 pg/m3 80 pg/m3 ~ u l ~ h u r ~ i o x i d e (SOz)

atter (RPM) (size less

Lead (Pb)

'bmmonial

CarbonMonoxlde (CO)

** (exceed but not on two consecutive days.

Residential, Rural & other

Average* 15pg/m7 Annual

Sensitive Areas

Method

24 hours** Annual

Average* 24 hours**

Annual Average*

24 hours** Annual

Average* , 24 hours**

8 hours** 1 hour

500 pg/m3 120 pg/m3

150 pg/m3 1.0 pg/m3

1.5 pg/m3 0.1 mg/ m'

, 0.4 mg/ m3 5.0 mg/m3 10.0 mdm'

200 pg/m3 60 pg/m3

100 pg/m3 0.75 pg/m3

1.00 pg/m3 0.1 mgl m3

, 0.4 mg/m3 2.0 mg/m3 4.0 mdm3

100 pg/m7 50 pg/m3

75 pg/m3 0.50 pg/m3

0.75 pg/m3 0.1 mg/m3

, 0.4 mg/m3 1.0 mg/ m3 2.0 mg/m3

- Resp~rable particulate matter sampler

- ASS Method after sampling uslng EPM 2000 or equivalent Filter paper

, - Non Dispersive Infra Red (NDIR) S D ~ C ~ ~ O S C O D V


I

Unobj : Unobjectionable Tless: Tasteless Class- A:Drinking water source without conventional treatment but after disinfection. Class-B: Outdoor bathing. Class-C: Drinking water source with conventional treatment followed by disinfection. Class-D: Fish culture and wild life propagation. Class-E: Irrigation, industrial cooling and controlled waste disposal.


DRINKINTG WATER QUALITY STANDARDS (AS PER IS: 10500) I S1 / Parameter and Unit I Desirable I Permissible Limit in 1

Limit Absence of Alternate Source

18 19 20

35 36 37

Fluoride (mg/L as F) Calcium (mg/L as Ca) Magnesium (me11 as Me)

Unobj: Unobjectionable Agrbl: Agreeable NR: No relaxation

Pesticides (pg/L) Alpha Emitters ( 1 0 ~ ~ p c / r n ~ ) Beta Emitters ( 1 0 " ~ c / m ~ )

1 75 30

1.5 200 100

Absent Nil Nil

0.001 0.0001 0.001

Annexure 6 : Audit Activities

Audit team was selected for the proposed job. It comprised of:

Dr. Mohit K Ray - Team leader, Environmental Specialist

Siddhartha Majumdar - Environmental Economist

Sumit Das - Chemical Engineer and Monitoring Manager

Besides, them time to time other members with specialised knowledge were consulted. Monitoring team comprised of experienced technical persons. They were supported by the SGS laboratory is an authorised laboratory of WBPCB having NABL and other international certifications.

Before starting the audit activities it is important to collect background information. For that two (2) sets of questionnaire were sent to the plant.

First Kick-off meeting for the study took place at the Plant office at Bandel TPS on 22 May 2207. The audit team first met the General Manager of the plant. Then the team met with the plant officials to discuss about the study. Plant officials present in the meeting were

Mr. S.S.Kar - Senior Manager, Civil

Mr. B.N.Baura - Senior Manager, C&FE Div

Mr. Anjan Roy - Manager (PS), Environment

Mr. Pranab K Ghosh - Junior Manager, Safety

Mr. Tapan Pathak - Assistant Manager, Fire Safety

In the meeting the questionnaires sent were discussed. Mr. Anjan Roy was selected as the nodal person for collecting and disseminating the information documents.

After that a number of meetings and plant visit have been taken place. A list of the meeting dates and venues are given below

Annexure 6 : Audit Activities

List of Meetings And Visits 0

Name of SGS personnel I Purpose Dr. Mohit Ray I Kick of meeting with BTPS personnel Mr. Sumit ~ u m a r Das

Dr. Mohit Ray Mr. Sumit Kumar Das

Dr. Mohit Ray Mr. Sumit Kumar Das

Mr. Shaoo and Mr. Rama Krishna of WB P

Mr. Dipankar De Sarkar Environmental monitoring 1 sample collection Mr. Sumit Kumar Das

Site visit & data collection

Site inspection & data collection

Meeting with WB and WBPDCL at Kolkata

Dr. Mohit Ray

& monitoring team Mr. Dipankar De Sarkar I Collection of data

Visit to WBPDCL's plant at Bakreswar

Mr. Sumit Kumar Das I

Mr. Sujit Majumder ) Guidance for making port hole for ESP 1 efficiency test

Mr. Sumit Kumar Das I ESP efficiency test Mr. Sujit Majumder & monitoring team Dr. Mohit Ray Meeting with Mr. A.K.Roy and Mr. Rama

Krishna of WB at Delhi Dr. Mohit Ray Site insvection & data collection Mr. Sumit Kumar Das Dr. Mohit Ray Site visit with Mr. A.K.Roy and Mr. Rama Mr. Dipankar De Sarkar Krishna of WB Mr. Sumit Kumar Das Dr. Mohit Ray Meeting with WB and WBPDCL at Kolkata Mr. Dipankar De Sarkar Mr. Sumit Kumar Das Dr. Mohit Ray Meeting with Anjan Roy, Site inspection for Mr. Dipankar De Sarkar ETP, visiting CW outfall into the river Mr. Sumit Kumar Das

I - ASIA-PACIFIC PARTNERSHIP on Clean Development and Climate APP PEER REVIEW PROGRAMME

Reduction of SPM in Flue: An inexpensive method

developed in house.

A Paper By

Parameters Design Actual Efficiency of ESP 99.4 99.4

Ash in Coal 25% 30 - 32%

Inlet Dust burden 21.52 gm/Nm3 24.50 - 27.77 gm/Nm3

SPM at ESP outlet 130 mg/Nm3 147 - 167 mg/Nm3

Prevailing Scenario Titagarh Generating Station

I

! I

I i

i f I

j i

i I i i !

I

I --,- L I I p p p - - - - J Constraints:

.No space I spare-able structural load for increase the size of ESP.

.High cost involvement I outage time for increasing size of ESP.

TITAGARH GENERATING STATION EFFECT ON SPM level for NH3 inlection for 2 ppm

Higher the SPM l e ~ l more the effect

Observation number

There is a optimum flow rate of Ammonia for a range of inlet dust burden. There is a maximum flow rate of Ammonia beyond which no effect observed. Better the distribution of Ammonia in Flue

0 I - tn = * * .

&&*. . CI

c F - a m CI &lr

Z m a rrrf

0 n 5 3

Q "+*

E TP * . 0 0 a -

a ' "i

E s * -3 L L L Q j

s .** a m- u,&= r F f+ w = u;S w - L Qp: o m .- cs my) -,zc 2 " X U , a m .- " m.5 , a E atn .D

s m = s

.D - L & == a 0 .= a m

5 5 3 a 0 L m ui o E ~ (no E i 0 0

o E ,, m z z E B - m

. - * - a s -3- > s =;9

E r w c , ~ ; = ~ a .- a a ~ , --

. L - 0 l , , f ; ; E E z o r g Q - u,sQ-a m L a a 3 - '= . L @ a s m = Q S

7 - m 0 0 z - Emu,, J : c 8 a 0 @ C C D ~ a a .- .- E a a - Qo ID n 0 B HEz L O L

0 63pE =5 s m

a- * 4 W S U , Q-W q)Q- m, -. L

- - L Z Q % P 3 O O 9% 0 0 c L L Q tn, . m g a s - - E c >. = " o w z " = $ E ~ ; i a L.D LnC ' 3 ~ C Z a

m a n a , 3 0 m L

I

I ASH HOPPER I SPM level reduced significantly: Can be maintained below 75mqlN m3.

DEPENDS on fo owing Chemica & Physi~.a conditions: I I 1

I I i

Flow Rate and Distribution of Flue Gas. I i I

Concentration & Size of Dust Particles. 1

Temperature & Moisture content in Flue Gas. SO3 (Sulfur Trioxide) content in Flue gas. Air Leakage in ESP. Unburned carbon percentage. Resistivity of Dust Particles.

I

Un~ted States EPA-600tR-04-072 July 2004

Electrostatic Precipitator (ESP) Training Manual

SELECTED EXERCPTS

Chapter 7 Enhancing the Performance of Existing ESPs-Mechanical

ESPVI 4.OW is a very useful tool to enhance the performance of an existing ESP. Modeling the ESP's mechanical and electrical design and intended operation will indicate its performance capability. Then by comparing the various aspects of ESP operation that will be addressed in this chapter, ESPVI 4.OW will predict how they affect that performance. Once this is done, decisions can be made on how to proceed with the enhancement in the most cost- effective manner.

To determine if the current operation of the ESP deviates from the original operation and design, some tests and determinations may have to be made. There are a number of approaches that can be used to enhance the performance of an under-performing ESP. Assuming the mechanical and electrical design of the ESP is satisfactory, the characteristics of the gas and dust entering the ESP can have a major impact on its performance.

One of the initial approaches is to check if the ESP's gas volume is higher than design, because of either operation with excess air or air leaking in upstream of the ESP. The next is to consider whether the gas temperature is higher than predicted, because of either air heater ash build up or combustion difficulties, since this may increase the electrical resistivity of the fly ash, as indicated in Figure 6-1, in addition to increasing the gas volume.

As mentioned before, poor gas distribution has an adverse effect on the performance of an ESP. Therefore, conducting a field check of gas distribution within the field area will confirm if corrections need to be made. Mitigation of field bypassing or ducting build up should be addressed during the field measurements. These field measurements will also allow an assessment of the effectiveness of rapping in terms of keeping the system relatively dust free in addition to checking the alignment of the discharge electrodes and collectors.

In Chapter 9, Troubleshooting, Fault Finding, and Identification, the electrical operating conditions should identify possible deficiencies in operation, as a result of obtaining V-I curves for each precipitation field. The main advantage of determining the V-I curves is that they can be taken while the unit is on line. Although correction of these deficiencies may be carried out only with the unit off line, the maintenance team will have some idea of the problems.

7.1 Increasing the Size of the ESP

From time-to-time, ESPs are increased in size. This is usually done when a major increase in performance is required that is beyond the capability of simpler approaches. This would be a major, costly undertaking for which there may not be an alternative.

Increasing the size of the ESP can be done in either of several ways. The first is to increase the height, which requires that the superstructure be raised and new internal electrodes be installed. The second is to add one or more additional sections, which of course requires the room to do it. A third possibility would be to increase the width of the unit.

7.2 Flue Gas Conditioning

From the coal and ash analyses and electrical operation, one can identify if the ESP is electrically operating under reverse ionization, or back corona, conditions. One approach to enhance performance on "cold side" applications is to modify the ash resistivity by the injection of chemical conditioning agents. Possibly the most widely adopted method is the injection of sulfur trioxide. Where reverse ionization conditions arise on "hot side" applications as a result of sodium migration in the collected dust layer, then injection of sodium salts is used to mitigate the effect of sodium migration in the particle matrix.

An assessment of the opacity traces and a chemical analysis of the inlet and outlet dusts should indicate if the plant is subject to reentrainment problems, either because of excessive rapping or because the fly ash lacks cohesiveness. As indicated, unburnt carbon or the presence of cenospheres is particularly subject to producing low cohesivity deposits. One approach to improving cohesiveness and reducing reentrainment is to inject small quantities of ammonia upstream of the ESP. The ammonia reacts with the sulfur dioxide and sulfur trioxide to produce ammonium salts, some of which will be fused at the operating temperature, helping to bind the collected particles together.

Table 7- 1 lists a number of situations in which flue gas conditioning has been successfully used to enhance the performance of the ESPs. A minimum emission reduction of 50 percent and a maximum reduction of some 90 percent were attained.

Table 7-1. Performance Enhancement from Flue Gas Conditioning Approaches

To minimize site installation costs, all equipment is largely skid mounted, pre-wired and checked prior to delivery. The site work is thus limited to the final injection manifold and distribution pipe-work, electrical hook-up, and interfacing with the plant control system. The basic approach to produce the conditioning agents for SO3 injection is for the system to convert the SO2 to the trioxide by means of a catalyst before being diluted with heated air and dispersion into the ductwork. For the ammonia system, liquefied ammonia is evaporated and mixed with air prior to injection into the flue system.

Sulfur Trioxide Conditioning For sulfur trioxide conditioning, the feedstock can be either liquefied sulfur dioxide or sulfur. The liquid sulfur dioxide is stored and evaporated adjacent to the plant and mixed with heated air before entering the vanadium pentoxide catalyst chamber. For sulfur feed stock, the sulfur is fired in a sulfur burner with a balanced amount of air to produce around a 5 percent concentration of S02. The SO2 is then passed through the catalyst chamber where the sulfur dioxide is converted to sulfur trioxide with an efficiency of some 95 percent. The sulfur trioxide exiting the catalyst bed is then diluted with hot air and passed through a distribution manifold into the ducting upstream of the ESP.

To maximize the conditioning effect, in a contact time of less than 1 second, it is important that the reagent gases are introduced into the flue gas having as wide a contacting area as possible. A typical injection manifold would comprise a number of probes spaced across the duct, each having injection nozzles positioned at the "centers of equal areas". To maintain the gas as active sulfur trioxide and to avoid corrosion and plugging within the gas distribution network, the manifold system is constantly maintained at a temperature above any potential acid dew point.

Investigations into the conversion of naturally occurring sulfur dioxide in the flue gases on power plants are being actively conducted as an alternative to imported feed stock conditioning. With these, a parallel side stream catalyst bed is installed upstream of the economizer, where the temperature is around 400 "C, and the raw flue gas passed through the catalyst to convert some of the sulfur dioxide to sulfur trioxide. These approaches, although avoiding the need to import feedstock material, not only impact the overall boiler efficiency, but also can prove very expensive in that the cost of new or replacement catalyst beds can be significant unless gas pre-cleaning is adopted. There is also a catalyst-aging factor to be considered, which will reduce the nominal design conversion efficiencies and hence produce potential ESP performance shortfalls.

Ammonia Conditioning The equipment for ammonia injection is simpler in that anhydrous liquefied ammonia is stored and evaporated adjacent to the plant and mixed with air before passing through a distribution pipe manifold system. Although 25 percent ammoniacal liquor, a by-product from a coke oven, can be used, this requires additional thermal evaporation prior to dilution. The lack of availability of ammoniacal liquor to the site may mean this approach is not viable in spite of a much lower cost and easier handling.

With some particulates, such as Australian high-silica-plus-alumina fly ashes, dual conditioning is required. This is achieved by having both a sulfur trioxide and ammonia injection system operating in parallel, as indicated in Figure 7-1, but injecting the ammonia upstream of the sulfur trioxide. This enables the ammonia to initially react with the gaseous sulfur dioxide to produce ammonium bisulfatehisulfite to enhance the particulate cohesiveness; the sulfur trioxide is then able to reduce the fly ash resistivity to improve ESP performance electrically.

The actual injection rate into the flue gas, usually controlled by microprocessor devices, can be up to 15 ppm by volume for each reagent. These tend to be site dependent and are controlled by feedback data from the boiler loading, the continuous emissions monitoring system, and the ESP electrical operation. The results carried out on ESPs employing flue gas conditioning indicate that, dependent on the application, flue gas conditioning can bring about a minimum emission reduction of 50 per cent and can approach nearly 90 per cent in certain circumstances.

Public Disclosure Authorized - World Bank · 2016. 7. 14. · Ash Handling System Comprehensive...

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