Professional Documents
Culture Documents
Executed By
Amit Kumar
Master of Public Systems Management
(Environment Management)Roll No-107/MPS/090006
1
June, 2010
2
Assessment of Noise Level
of a Thermal Power Plant
Executed By
Amit Kumar
Master of Public Systems Management
(Environment Management) Roll No-107/MPS/090006
June, 2010
1
Contents
Executive Summary
2
2.0 Introduction
Life is powered by the coal-fired thermal power plant that contributes 2% (2000
MW) of the total power generation (40494 MW) in India. The share of hydel
power is around 25- 30% (25000 MW) while the rest 3-5% is due to nuclear
power and wind resources. Thermal power plant is one of the noisiest factories.
Ambient air monitoring, stack emission monitoring, water and effluent testing
are mandatory to compliance the needs of pollution control board to run the
industry. Many industrial authorities as well as pollution control boards do not
give due weight age to the problem of noise pollution because it does not
jeopardize employee’s life immediately after exposure. However, prolong
exposure to industrial noise can’t be neglected which may be the cause of
neurobehavioral change, psychological stress and unhappiness in daily life
without showing the symptoms of chronic / acute diseases. Since, the ears have
no natural device to check or protect it from noise; it has no option but to receive
3
all the sound that strikes the eardrum. In industry, excessive noise exposure can
cause both auditory and extra-auditory effects. The most important of these is
hearing damage resulting from prolonged exposure to excessive noise. Another
undesirable effect is speech interference or interruption of communication.
Annoyance is a third undesirable effect of noise.
(3)Frequency of occurrence,
(4)Susceptibility of individual,
4
• To assess the possible health effect on the workers working in the high
noise zone based on the threshold limit of American Conference of
Governmental Industrial Hygienists.
5
three nos. seal air fans (50% capacity each), supply the pulverized coal to be
titled in the vertical plane by a burner tilting arrangement basically for
controlling the stream temperature.
To ensure increase safety, reliability and care in operation, the fuel firing system
is equipped with Burner management System (BMS) for No. 4 Boiler AND furnace
safeguard supervisory system (FSSS) for unit No. 5 & 6 Boilers.
Two Nos. constant speed forced draft fans and two Nos. variable speed Induced
draft fans are provided to supply the combustion air and no exhaust the flue gas
chimney respectively.
Both the fans are electric motor driven. The F. D Fans taking suction from
atmosphere through inlet regulating vanes discharge air into the Air Heaters. The
heated air from the Air Heaters passes through two Nos. hot air ducts on the
sides of the boiler to a common burner wind Box. The secondary air from the
wind Box enters the furnace around the burner through air registers (for No.4
Boiler) and through Sec. Air Control Damper (for 5&6 Boilers).
The flue gas leaving the economizer enters the stationary rubular air heaters (for
No. 4 Boiler)/rotary air heaters (for No. 5 & 6 Boilers). For No. 4 Boiler Air Heater
air out let supplies required air for secondary air as well as primary air for P. A.
Fans, whereas for No. 5 & 6 boilers’ rotary air heaters heated up air discharged
by P. A. Fans. The gas leaving the air heater passes through the electrostatic
precipitator before entering the ID Fans Inlet.
All the three turbines for unit Nos. 4, 5 & 6 are of BHEL make, C-210MW turbine
which are condensing tandem compound, three cylinders, impulse type machine,
with nozzle governing and regenerative feed heating. The double flow LP Turbine
incorporates a muil0exhaust Baumen Stage in each flow. The Steam after
expanding through twelve stages of HP Turbine is reheated in the reheater at
Boiler and returned to the IP turbine through IP control valves. After expending
through eleven stages of IP and four double flow stages of IP turbine, it is
exhausted to the twin surface condensers welded directly to the exhaust part of
LPT.
The rated output of the generator is 210 MW with main stream parameters
before Emergency stop valve (ESV) being 130 at, and 5350C at inlet to the
interceptor valves. The HP and IP rotors are connected by a rigid coupling and
have a common bearing. The IP & LP rotors are connected by a semi flexible
coupling.
The direction of rotation of the rotors is clockwise viewed from the front
bearings. The common bearing of HP and IP rotor is combined journal-cum-thrust
bearing. The turbine is anchored at the middle foundation frame of the front
exhaust part of the LPT. The turbine expands barely by 32 mm to words the front
bearing and by 3mm towards the generator is steady state operation at full load
with rated parameters. The turbine is equipped with a barring gear which rotates
the rotor at 3.4 r.p.m.
6
Figure 1 and 2 present process flow chart of circulating water and air & flue gas
system at the Kolaghat Thermal power plant.
COOLING
TOWER COOLING
UP PUMP
PRE-
TREATMENT
COOLING
TOWER
RESERVIOR
(1,2&3)
COOLING TOWER
CONDENSER
(4,5&6) POST
TREATMENT
PLANT
7
ACW PUMP
FOR COOLING
OTHER
T
F.D. FAN
M
AIR PRE HEATER
O
S
RURANCE
P
H PRIMARY
FLUE
E
AIR FAN
R COAL MILL
PLATEN SH
E
ATMOSPHERE
RE-HEATER
CHIMNEY
FINAL
SH
I.D FAN
LOW TEMP
SH
8
Figure 2: Process Flow Chart of Air & Flue Gas System at Kolaghat
Thermal Power Plant
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Mixed Bed Unit supply high quality water to the steam cycle make up and to the
make up to the closed cycle D. M. cooling system.
The compressed air required for various instruments are met by two nos
Instruments Air Compressors for each unit. Two Nos Plants Air compressors are
also provided for each unit for supply of service air, air to ash handing system,
BOBR unloading system etc. Both the system is provided with air drying
equipments.
The fly ash in the boils is collected in Electrostatic Precipitator located in the flue
gas path between air heater and ID Fans. The bottom ash is collected in a water
impounded hopper located at the bottom of the furnace. The fly ash removal is
done by hydro-pneumatic system with the help of an air separator, hydro
exhauster and dry ash transport lines, dust extraction valves etc. and the system
is automatic sequentially operated. The bottom ash is removed by hydro-ejecting
system, which utilizes high velocity water to remove the ash after being crushed
by clinker grinders located below the bottom ash hopper.
The coal requirement of the 3 Units, about 8000 T/day, is met by coal handling
plant. The coal in Box wagons is unloaded by 2 Nos. wagon Tipplers and BORR
wagon are unloaded at Track Hopper. Transfer points of coal to bunkers is
achieved by double route of coal Conveyors along with crushers, transfer points
etc. (8000T/hr. capacity). Picker0boys have been engaged to separate stones,
foreign materials etc. present in the coal before crusher and finally after crusher.
Each 210MW generator is connected to 400KV grid through 250 MVA delta-star
step-up transformers for Stage –II. For supply of auxiliary power for each unit
auxiliaries, 2 Nos UTAS each of 16MVA capacity are connected to the outgoing
bus of wach generator. SF-G breakers with isolators are provided to connect HV
side of Generator – Transformer to the 400KV grid. To supply auxiliary power
during start up, shut down or in case of unit auxiliary power failure, two nos
Station. Auxiliary Transformers (SAT) each of 31.5MVA capacity are included in
the system. These STTS also system of two Nos Inter Bus Transformers (IBTs).
The inter Bus Transferors (315MVA) each are used to interconnect 400KV Bus of
Stage – II with 220KV Bus of Stage – I and also supply 44KV power to SATs. There
are two Auto Transformers (150MVA each which receive power from 220KV Bus
and supply 132KV to 132KV Bus. At Stage – I there are two bus. Reserve
Transformers (31.5 MVA each) which receive power from 132 KV and supply 6.6
power to Station Auxiliary Bus like stage – II SATs.
The 6.6 KVLV Output from Auxiliary transformers and reserve transformers are
further stepped down to 415V through suitable transformers for feeding low
voltage auxiliaries. For supplying necessary D. C. power for emergency drives,
protections and interlock circuits, a 220V station D. C. System with battery and
battery charger has been installed. Moreover, 3 Nos Diesel Generating set (1
MVA each) have been provided to supply 415 power to all power to all the six
survival power.
For evacuation of 400KV power, Single jeered Feeder (capacity 600MW), single
Talcher Feeder (capacity 600MW) and single Durgapur Feeder (not completed) of
capacity 600MW have been provided. Foe Evacuation of 220KV power, double
Howrah Feeder (180 MW each) have been provided. Double Kolaghat Feeder (90
MW each) and double Haldia Feeder (90MW each) are connected with 132KV Bus
for evocation of Power. To increase the capacity of these Kolaghat &Haldia
132KV feeders, one more 220KV/132KV Auto Transformer (150MVA) has been
proposed to be installed.
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5.0 Methodology of Noise
Measurements
Survey Techniques
Cirrus sound level meter, model 236 A, UK make sensitive to sound pressures
between 20 and 20000 Hz was used to measure the noise level. Calibrated
instrument was transported in a brief case containing sponge groove that protect
from vibration and shock. The range and sensitivity of the instrument is 32-140
dB (A) with accuracy ± 5% [12] the noise level was recorded at a distance of 5-
10 feet on the basis where cumulative noise was expected from different sources
or at operator. Monitoring was done at a height of 1.5 m and 1m away from the
chest for 30 mm at an interval of ‘15 5.
Principles of Leq
The short Leq (equivalent continuous sound level) concept was proposed by
Komorn and Luquet.”3 Leq is the level which, if maintained constant for the
same period as the measurement, would contain the same amount of energy as
the fluctuating noise level. It is measured directly by an integrating averaging
sound level meter. It is a linear integration over time. The formula used for Leq
calculation is given below in the form it appears in the international standard IEC
804.
Among
A-weighting (ears response to sounds near the 40 dB level),
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C-weighting (near 100 dB)
5.1 Monitoring location
Alter primary walk through the survey, 13 locations of plant area had been
identified based on the maximum sound pressure for noise measurements.
These locations are shown in Table 1 along with short description of the noise
sources and the specific function of the noise source/machines.
These are: -- Besides the above major sources which contribute —80 % noise,
the remaining noise might be attributed to the background noise generated from
incoming /outgoing vehicles, servicing and repairing, minor construction, office
work etc.
12
Coal unloading plant-2
Coal crusher plant- 3
Compressor - 5
Boiler feed pump-7
Operator sitting place for boiler feed pump-I
Control room-4
Operator sitting place-2
Turbine -8
Boiler operating room-I
Boiler operator sitting place-I
E D. fan-8
I. D. fan-a
Operator sitting place of I. D. fan-6
D. M. plant-I
Cooling tower-I
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Table 1: Monitoring Locations, Noise Sources and Particular Function of the Machines
Compressor Noise
The minimum event Leq, 81 dB (A) was recorded near Compressor-3 and while
the maximum event Leq, 93.6 dB (A) was recorded near compressor-I with log
average Leq 90.54 ± 2.41 dB (A). All the compressors were producing noise level
which touches the maximum permissible limit of 90 dB (A) for 8h. Especially
compressor-I showed levels beyond the maximum permissible limit of 90 dB (A)
for 8h /day [Table 2]. Compressors generated second highest log, average Leq
89.98 dB (A) noise level after the ED. Fan with log average Leq 95.91±6.45 dB
(A) [Table 2]. These data do not fall in the safe zone for occupational
environment; out of 5 compressors; 2 were producing beyond the permissible
limit of 90 dB(A) [Table 4].
The minimum event beq, 81.5 dB (A) was recorded near 13FF- 5A and while the
maximum event beq, 92.4 dB (A) was recorded at I3FP-313 with log average beq
89±1.16 dB (A) [Table 2]. All the I3FPs were producing noise level which touched
the maximum permissible limit of 90 dB (A), especially; I3FF-313 showed beyond
the maximum permissible limit of 90 dB (A) for 8h/day.
Turbine
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The noise level found between 14.9-86.0 dB (A) with log average beq
83.44±3.82 dB (A). The lowest was measured for turbine No. 6 while highest for
turbine No. 2 and 8. Turbine sound pressure is lesser than ED. fan, boiler feed
pump but higher than I. D. fan and cooling tower. It produced almost equivalent
sound pressure of DM plant and aerial rope way [Table 2].
F.D fan
The minimum event beq, 83.8 dB (A) was recorded for ED. fan No. IA and while
the maximum event beq, 103 dB (A) was recorded for E D. Fan No. 6A. With log
average beq 95.94 ±6.45 dB (A). E D. Fans were the noisiest one among the
power plants. F D. Fan Nos. 2A, 3A, 4A, 5A, IA and 9A produced noise level of
about 85.1, 95.8, 94.9, 88.6, 92.1 and 90.5 dB (A) respectively [Table 2].
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Table 2: Noise Levels dB (A) at Different Locations of a Thermal Power Plant
Source:
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Table 3: Noise Levels dB (A) at Different Locations of a Thermal Power Plant
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Table 4: Threshold Limit, Values for Non-Impulsive Noise (Adopted in 1970 by the
American Conference of Governmental Industrial Hygienists)
Source: The Noise Pollution (Regulation & Control) Rules, 2000, Gazette of India
vide SO 123(E), dated 14.2.1998 and subsequent amendment vide SO 1013 (E)
dated 22.11.1998
I.D. fan
The minimum event Leq11.1 dB (A) was recorded for ID. Fan No. IA while the
maximum event Leq, 83.8 dB (A) was recorded for I. D. fan No. 5A with log
average Leq 81.11±2.22 dB (A). ID. fan is comparatively better than E D. fans in
terms of noise level [Table 2].
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Control room
The noise level ranged between 61.9-12.5 dB (A) with log average Leq
90.31±4.93 dB (A). The least sound 61.9 dB (A) was felt at control room no. TG-5
while the maximum sound, 12.2 dB (A) at TG-8 [Table 3].
The noise level range is between 83.1-83.2 dB (A) with log average Leq
83.15±0.01 dB (A). The least sound 83.1 dB (A) was felt at TG-4 while the
maximum sound, 83.2 dB (A) at TG3 [Table 3].
However, there is no unsteady / impulse noise in the power plant which affect
more adversely than steady noise. Indian noise standards are also high than the
standards for other countries. For example, the working hours in Belgium,
Denmark, France, Sweden and Soviet Union (Russia) are 40 h/week but in case of
India there are six working days in a week, so the total exposure hours are
48h/week [Table 7]. Hence, revision of the standard is required at par with the
international/ European standard
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7.0 Suggestions &
Recommendations
Noise can be controlled by designing and fabricating new engines and by
setting a noise limits at least 5-10 dB (A) below the prescribed standard.”6
Transmission control may be achieved by covering room walls with
acoustic tiles as sound absorbers. Supply of earplug, earmuff and cotton!
Woollen to its employees help in protecting exposed person. Preferably,
shifting of duty from a particular equipment to another on alternate days.
Normal duty hours can be reduced at high noise generating sources.
Isolated cabin is required for operator where it is not available. Employees
must be made aware and educated about noise nuisance through
adequate publicity. The irregular use! Not use of safety measures are a
common scenario in most of the industries where rules and regulations are
liberal hence authority can make it mandatory to use one or other type of
noise protective measures at noisy places.
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Sound Absorption treatment:
Source: The Noise Pollution (Regulation & Control) Rules, 2000, Gazette of India
vide SO 123(E), dated 14.2.2000 and subsequent amendment vide SO 1046 (E)
dated 22.11.2000
The plants act as a very good barrier for absorption of noise. The
development of green belt in and around industrial complex/commercial
and residential areas can act as noise barriers. They can reduce noise
level by absorption by ground cover and tree foliage. A wide green belt of
thick vegetation can be produced around the factory premises. This will
absorb to a large extent and dissipate sound energy and thus act as buffer
zone.241 A tree belt 50 m wide and of different height can reduce the
noise level up to 20-30 dB(A).’12 GBD will reduce the noise intensity by
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creating obstruction in its transmission path. In addition, it can decrease
substantial amount of the air pollution load. Vegetation plays a positive
role for our eyesight potential and GBD also regulates the temperature
through transpiration. GBD also purifies the atmosphere to a significant
level by utilizing CO 2 produced in the power plant and releasing O 2 during
photosynthesis and enhances the aesthetic beauty.
8.0 Conclusion
This current investigation may help power plant authorities to
adopt preventive measures and for deciding future strategies
to combat the menace of noise pollution with scientific
approach. This will ensure in providing better environment to
the employees. Occupational health hazards have to be
assessed by an expert agency, which also correlates noise
pollution and health hazards. Science and technology have not
reached up to the level by which soundless machine can be
made but the preventive measures could be adopted for
prevention, abatement and control of substantial amount of
noise level.
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9.0 Reference
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noise on blood pressure and Heart rate. Arch Environ Health
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3. Crocker MJ, Price J. Noise and noise control. 18901. CRC Press mc:
Cranwood Parkway, Cleveland, Ohio; 1975. p. 44128.
4. Singh AP, Rai RM, Bhatia MR. Effect of chronic and acute exposure to noise
on physiological function in man. Tnt Arch Occup Environ Health 1982;50:169-74.
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7. Glorig A. Non-auditory effects of noise exposure. sound and vibration,
27101. E. Oviatt: Ohio 1971. p. 44140.
9. Anticaglia JR. Noise measurement and acceptability criteria. In: the Industrial
Environment its Evaluation and Control. US Dept. of Health and Human Services,
Public Health Service, Centre for Disease Control, National Institute for
Occupational Safety and Health: 1973. p. 309- 19.
11. Kazi Rehan A. Noise induced hearing loss-an occupational hazard. Indian J
Occup Env Med 2002;6:207-12.
12. Acoustic and Vibration measurement for industry. CRL 236 A operating
manual, Cirrus Research Ltd., Acoustic House, Hunmanby: N. Yorkshire, United
Kingdom; 1994. p. 1- 8.
14. Roberts HC. Noise pollution. In: Environmental engineers handbook. Liptak
BG, editor. V-ITT Land pollution. Chilton Book Company: Radnor Pennsylvania;
1978.
16. Natu M, Solanki SR. Noise survey and effects on state transport bus drivers.
Indian J Occup Hith 1977;20:195-200.
17. Chaddha SL, Singh TA. Survey of noise assessment and its effect on hearing
of workers in ammunition factory. Indian J Indus Med
25
1977; 17:93-103.
20. Santra SC. Status of noise pollution studies in Calcutta and current state of
legal measures for abatement. In: Proceeding of the National Workshop on
Environmental Statistics, Goa, Central Statistical Organization, Department of
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21. Sharma PD. Environmental biology and toxicology. Rastogi and Company:
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