NTPC TRAINING REPORT

PREPARED BY:

SHYAM SUNDARAN
08BEE146
VIT VELLORE
 TABLE OF CONTENTS

Content Page No.

Acknowledgement 3
Abstract 4
About the Company 5
Introduction 6
Safety and Disaster Management 8
Control and Instrumentation dept. 14
Maintenance and Planning dept. 18
Operations (Mech.) 19
Operations (Electrical) 28
Conclusions 33
References 34

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 ACKNOWLEDGMENT

I would like to thank the management of NTPC for their

support during the duration of my training in the organisation. I
would also like to thank the employees at NTPC for their
invaluable support and guidance without which this project
couldn’t have been completed successfully. I would also like to
thank my professors for their whole hearted motivation and
guidance which has gone a long way in the success of this
project.

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 ABSTRACT

This report contains the details of findings and observations

during the course of training at NTPC-Faridabad. This also
contains the details of the plant with an insight into its working
and maintenance. Every effort has been made to present this
report in a factual and in a precise manner.
This report contains the working and the role of the various
departments which work 24x7 in order to make the plant work
in an efficient and safe manner.

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 ABOUT THE COMPANY

NTPC Limited is the largest thermal power generating company

of India. A public sector company, it was incorporated in the
year 1975 to accelerate power development in the country as a
wholly owned company of the Government of India. At present
the GOI holds around 89.5% of the total equity shares of the
company and the balance 10.5% by the FIIs, Banks, Public and
others. Within a span of 35 years, NTPC has emerged as a fully
national power company with power generation facilities in all
the regions of the country. The chat below shows the growth of
the company till the year 2007.

NTPC’s core business is engineering, construction and

operation of power plants. It also provides consultancy in the

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area of power plant construction and power generation to
companies in India and abroad.

INTRODUCTION

NTPC-Faridabad was approved on 25th July 1997. The total

project cost was 1163 crores INR. The plant was fully functional
in the year 2000 with an installed capacity of 432 MW. The
plant under an agreement with the Harayana government
supplies the entire power generated to the state of Haryana only.

Salient Features of this project are:

1. Project: Faridabad Gas Power Project

2. Location: Village Mujedi, P. O. Neemka, Faridabad, Haryana

3. Plant Capacity: 432 MW

4. Plant Configuration: Gas Turbine 1 - 138 MW

Gas Turbine 2 - 138 MW
Steam Turbine - 156 MW

5. Mode of Operation: Base Load

6. Fuel: Natural Gas

7. Alternate Fuel: Naphtha / HSD

8. Average Gas requirement: 2 million cubic meters per day

9. Fuel Source: HBJ pipe line (through GAIL)

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10. Cooling water: Rampur Distributory source

11. Naphtha Storage: 2 tanks of 800 Kl. Capacity each.

12. HSD Storage: 1 tank of capacity 400 Kl.

13. Power Evacuation: 2X220 KV Double circuit lines to220KV

BBMB sub-station at Samaipur (Ballabgarh) 2X220 KV

Double Circuit lines to 220 KV HVPN sub-station at Palla
(Faridabad)

NTPC-Faridabad is a power (electricity) generating company

with installed plant capacity of 432 MW. The plant
configuration is as under:

Gas Turbine -1 138 MW

Gas Turbine -2 138 MW
Steam Turbine 156 MW

The mode of operation is “Base Load”. Natural Gas is used as

main fuel. Naphtha is used as an alternate fuel. Average gas
requirement is two million cubic meters per day. Gas Authority
of India Ltd. supplies Natural Gas to the plant through their
H.B.J. Gas pipeline. The electricity generated is supplied to the
state of Haryana.

The liquid fuel which is used during a gas shortage is supplied

to NTPC-Faridabad by Indian Oil Co. (IOCL).

Water which is an important pre-requisite for any thermal power

plant is obtained through the Agra canal which runs through the
Faridabad city.

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The Gas turbines used at NTPC–Faridabad is obtained from
SIEMENS which is the OEM(Original Equipment
Manufacturer). The model used in this plant is V 94.2(model-3).

SAFETY & DISASTER MANGEMENT AT FGPP

“PREVENTION IS BETTER THAN CURE”

Types of Hazards in Industries:

1. Mechanical

2. Electrical

3. Physical

4. Chemical

They are explained as follows:

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 Mechanical

Due to moving parts –

Rotors, blades,
Flywheels, Pulleys,
Belts, Couplings, Cams,
Spindles, Chains,
Cranks, Gears,
Sprockets, Shafts, Rods
Where Mechanical Hazards
Occur
The point of operation
Power transmission
apparatus

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 Safeguarding strategies

1. Guards
i) Fixed
ii) Interlocked
iii) Adjustable
iv) Self-adjusting

2. Devices
i) It may stop the machine if a hand or any part of
the
body is inadvertently placed in the danger area.
ii) Restrain or withdraw the operator's hands from
the
danger area during operation.
iii) Require the operator to use both hands on
machine
controls.
iv) Provide a barrier which is synchronized with
3. Location
the & Distance
i) Walls
operating cycle of the machine in order.
ii) Barriers/Fences
iii) Height above worker
iv)Size of stock (single end feed, punching)
v)Controls (positioned at a safe distance)

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4. Feeding & injection

i)Automatic Feeding
ii)Semi-Automatic Feeding
iii)Automatic Ejection
iv)Semiautomatic Ejection
v) Robots

5. Miscellaneous Aids

i) Awareness barriers
ii) Ropes
iii) Shields
iv) Holding tools
v) Push sticks or blocks

ELECTRICAL HAZARDS

1. Direct-Direct electrocution.

2. Indirect-Damages due to current. E.g. Fire.

3. Induction-Electromagnetic field.

PRECAUTIONS

1. Wires at safe distances from workers.

2. Automatic system-Much effective than the manual

method.

3. Reducing exposure time.

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 PHYSICAL

1. Heat

2. Light

3. Noise

4. Fire

5. Pollution

Precautions

Heat-
Reduce exposure time.
Water coolers at every place.

Light -
Personal protective equipments.

Noise -
Acoustic materials.
Personal protective equipments.

Fire -
• Fire extinguishers at all critical points in the plant.
• In house fire station managed by the CISF.

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 FIRE FIGHTING SYSTEM:

NTPC-Faridabad has full-fledged Fire Fighting System to

safeguard against any kind of eventuality. It has fire fighting
hydrant system, which remains operational round-the-clock. It
has fully automatic system involving state-of-art technology to
fight against any kind of fire arising due to gas/naphtha leak.
Also, there is Natural Gas Leak Detection System, Naphtha
Leak Detection System.

CHEMICAL HAZARDS

1. Industry specific.

2. Dust, ash are the by-products.

3. NTPC-Faridabad- chlorine, alkali, acids.

4. No problem of waste disposal as the main by-product is

water.

PRECAUTIONS

1. Leakage detectors at each chemical tanks.

2. Chlorine physically detected by Ammonia.

3. Chlorine siren should be present.

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 GENERAL SAFETY MEASURES

1. Automated plant reduces the risk of human error.

2. Skilled labour must be employed as their

knowledge reduces chances of mistakes

3. Regular check-up of the plant and the machinery

should be done at regular periods by the MTP dept.

4.Personal protective equipments such as helmets must

used in the plant.

5.Adequate banners and signage must be present to

make the people aware of the hazards and the
dangers around.

6.Regular drills and training must be given to the

employees to deal with any kind of emergencies.

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 CONTROL & INSTRUMENTATION
DEPARTMENT

The Control & Instrumentation Department(C&I) is responsible

for the operation and of all the electronic sensors, actuators and
controllers besides maintaining the pressures, temperatures,
level and the flow in the various tanks, pipes and also in the
various heat exchangers present in the plant.

The main functions of the C&I dept. at NTPC-

Faridabad are:

1.Measurement and display of various parameters.

2.To control the various parameters by Automatic feedback

controlling which involves the taking of decision based on
inputs from measurements by the processor.

3.Protection of various equipments(pumps, generators etc..) and

workers from hazards by automatically tripping a cycle when
hazardous conditions are reached.

4.Alarm generation in case of a mechanical or an electrical

failure.

The Faridabad plant has outsourced its automaton to various

companies on a Package Based Deal.

The C&I dept. besides also undertakes the modifications or

upgradadion of it’s systems.

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The C&I dept. uses various instruments in its functioning.
They can be broadly classified as:
1. Sensors
2. Controllers
3. Actuators

Sensors

1. Sensors are instruments used for measurement

purposes.

2. They measure various parameters and convert them

to electrical output which is supplied to controllers.

3. This data is then displayed which aid the engineers

make the judicious decisions.

These sensors measure the following parameters:

1. Level of fluids in pipes and tanks.

E.G: LVDT can be used for this measurement

2. Flow of fluids such as fuel steam etc.

Done by sensors such as Venturimeters or Rotameters.

3. Pressure in tanks and pipes also can be measured

It’s done by sensors such as Gauges, Pressure Switches,
Capacitive Transducer etc.

4. Temperatures can be measured anywhere in the system.

Instruments such as Thermocouples and RTDs are used.

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 Controllers

These are devices which receive data from the sensors,

process it and give instruction to the actuators based on the
processed data. They are analogous to the human brain.

Various types of control systems used at NTPC-

Faridabad are:

1. Single control system

This consists of a single processor which controls the

entire process. This system is not quite efficient as it draws
large amount of power and also if the processor fails then
the entire unit has to stop.

2. Distributed control system

This consists of various processors which are responsible

for various parts of the process and have a channel of
communication between them enabling them to work
efficiently. Such a system is more efficient and is
favoured.

DCS is extensively used within the plant to control various

processes of the plant.

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 Actuators

Actuators are analogous to motor organs like hands or legs

of the body. Actuators are the instruments which are responsible
for carrying out control commands from the controller like
closing of a valve etc.

Actuators are of manly three types:

1. Pneumatic Actuators

These actuators carry out mechanical tasks using

compressed air. These are very accurate but are not very
strong and get damaged easily. The pressure in it is
in the range of 3-15 psi.

2. Hydraulic Actuators

These use the pressure of compressed oil to perform

their tasks. These actuators are quite strong but lack
a high degree of accuracy.

3. Electronic Actuators

These make use of electronic motors to perform their

tasks.

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MAINTENANCE & PLANNING DIVISION (MTP)

It is basically divided into two other divisions namely:

1. Mechanical maintenance
2. Electrical maintenance

This dept. is needed because of the below stated reasons:

1. To take up the daily maintenance of the plant as per

schedule.

2. It is not possible to maintain the plant daily so a schedule

is needed which is drawn up by this dept.

3. It takes up rectifying work in case of a machine or an

electrical failure.

4. It is responsible for the overhauling of the plant.

5. It monitors the condition and the working of the plant to

check if everything is working well.

6. It arranges for spares from the OEM(Original Equipment

Manufacturer) and also from other suppliers.

7. This dept. also oversees the work of the workshop within

the pant whose work is to manufacture small parts.

8. The MTP also undertakes the regular calibration of all the

instruments and the sensors.

9. There is a weekly meeting for contracts and material in the

dept.

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 OPERATIONS (MECHANICAL)

The O&M(mech) dept. at NTPC- Faridabad takes care of day

to day running the mechanical components of the plants in a
safe and in an efficient manner. The main mechanical
components are listed below:

1. Gas Turbine
2. Steam Turbine
3. Pumps
4. Heat Recovery Steam generator(HRSG)

GAS TURBINE

PRINCIPLE OF GAS TUBINE:

1. Works on Brayton Cycle

2. It is an open cycle process
3. Isentropic compression and expansion takes place.
4. Constant pressure heat addition takes place.

The Gas Turbine used at NTPC-Faridabad is V94.2 (model-3) is

manufactured by SIEMENS, Germany which is the OEM.

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VIEW OF THE TURBINE AND THE COMPRESSOR
COUPLED TO IT MANUFACTURED BY SIEMENS

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A VIEW OF THE AIR SUCKING MECHANISM FOR
THE COMPRESSOR AT NTPC-FARIDABAD

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Schematic of a steam power
plant

SCHEMATIC OF A STEAM POWER PLANT

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LINE DIAGRAM SHOWING GAS TO ELECTRICITY
CONVERSION AT NTPC-FARIDABAD

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 STEAM TURBINE

Manufactured by BHEL-India. The flue gases from the gas

turbine are passed through the Heat Recovery Steam
generator(HRSG) since the gases have high thermal energy
and are at a temperature of upto 540 degrees. The flow chart
of the steam build up is shown below:

Start up steam flow

steam

HP reducing station, start-up flash tank

steam

Reheater (for cooling)

steam

LP bypass station (reducing station)

steam injection water

saturated
steam

condenser

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A VIEW OF THE STEAM TURBINE GENERATOR

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HEAT RECOVERY STEAM GENERATOR(HRSG)

When the plant is running in open cycle i.e. when the gas
turbine is only running then the efficiency is a mere 30% but if
we run the plant in a closed combined cycle which includes the
gas as well as the steam turbines then we can achieve an
efficiency of about 50%. Thus it is profitable to run the plant in
a combined cycle mode.

The flow diagram of a combined cycle power plant is given

below:

COMBINED CYCLE PLANT HEAT

45.9 %

GT
STG
POWER(30%)
POWER(15.9%)

STACK LOSS(14%)
EXHAUST
FUEL(100%) GAS TURBINE HEAT(67%) CONDENSER
LOSS(34.3%)

MISC.LOSS(3%) MISC.LOSS(2.8%)

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HRSG CONSTRUCTION

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 OPERATIONS (ELECTRICAL)

The OPERATONS (ELECTRICAL) dept. at NTPC-

Faridabad takes care of the running of the electrical systems as
well as maintaining them.

The electrical overview of the plant is shown below:

HV SYSTEM CONTROL ROOM

STEP UP
TRANSFORMER LV SWITCHGEAR

AC & DC
HV- BREAKER AUXILIARY
SYSTEMS CONTROL
SYSTEMS

2 1
AUX. PROTECTION
TRANSF.

GOVERNOR
GENERATOR
1 BREAKER 2
STATIC
STARTER

PT’s
&
CT’s
SYNCHRONIZING

EXCITATION
SYNCHRONOUS SYSTEM
TURBINE GENERATOR

STAR
POINT EXCITATIONTRANSFORMER
CUBICLE

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 General Classification of Electrical Systems

ELECTRICAL SYSTEMS

AC 50 Hz SUPPLY SYSTEM D/C SYSTEM

220 KV 3 PHASE FOR BULK 220 V FOR UPS &

POWER TRANSMISSION EMERGENCY SYSTEMS
10.5 KV,15.75 KV 3 PHASE 24 V FOR SOLENOIDS,
GENERATOR OUTPUT
VOLTAGE CONTROLLERS

6.6 KV 3 PHASE FOR STATION

AUXILLIARIES 48 V DC IN SWITCHYARD

415 V 3 PHASE FOR LOW VOLTAGE

AUXILLIARIES

240 V SINGLE PHASE SUPPLY

Generally the D/C systems are placed to draw power for starting
of the systems of the plant in case of a grid failure.

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DETAILS OF THE GAS TURBINE GENERATOR

Apparent power 170.12MVA

Active Power 144.6MW
Current 9354A
Voltage 10.5KV+/-5%
Speed 3000rpm
Frequency 50Hz
Power Factor 0.85
Stator Winding YY
Rated Field current 833A
Rated Field Voltage 410V

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 DETAILS OF THE STEAM TURBINE
GENERATOR

188.23MVA
Apparent power
160MW
Active Power
Current 6900A
Voltage 15.75KV+/-5%
Speed 3000rpm
Frequency 50Hz
Power Factor 0.85
Stator Winding
YY
Rated Field current
Rated Field Voltage 798A
432V

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 TRANSMISSION DETAILS

220 KV Switch yard at FGPS

1. 3 Nos Generator Circuits (GT-1,2,ST)

2. 2 Nos Palla lines
3. 2 Nos Samaypur lines
4. Bus coupler
5. Transfer bus coupler

220KV SWITCH YARD -FGPP

SAMAYPUR-1&
PALL-1&2
2

BUS-1

B/C
BUS-2

TRANSFER BUS

TBC GT-
GT-1 2 ST

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 CONCLUSION

To summarise the above mentioned report all the departments

were thoroughly studied and all the information was gathered
regarding the plant and its auxiliary units.
The purpose of this training was to get an insight into the
functioning of a power plant with particular emphasis on its
electrical systems.
Finally I would mention the exemplary service that the
management and the staff of NTPC give to the nation.

REFERENCES

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1. wikipedia.com
2. ntpc.com
3. scribd.com

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